ICS Tunnel Master Jr User Manual

TUNNEL MASTER JR MANUAL

Welcome

Welcome, and thank you for purchasing your new Tunnel Master Jr. Car Wash Controller
from Innovative Control Systems, Inc.

As an ICS customer you benefit from a thoroughly researched car wash controller system.
This manual, “ICS Car Wash Controller System” has many features, which will enable you,
the operator, to have an active part in the control and operation of your car wash facility.

Controller Features:

• 24 programmable, fused outputs, upgradeable to 48, each with two independent circuits

for 24vac and 110vac

• Programmable relay flashing feature

• Exclusive, patented anti theft feature to prevent unauthorized processing of car washes

• Input for Pulse, Gate, Tire, Roller Locator, Entrance Management and Panic circuits

• Auto pulse feature allows pulse simulation in the event of pulse switch failure

• Auto Gate feature allows gate switch simulation in the event of gate switch failure

• Exterior indicators for easy troubleshooting

• 16 programmable service buttons on the entry keypad, upgradeable to 32

• Automated wet down feature for easy 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 maximum value from the system.

• Furnish operators with a tool for training their employees on the OEM Car Wash

Controller.

By reading the information and performing the procedures in this manual you should
be able to:

• Install your Tunnel Master Jr. Controller

• Configure your wash settings and features

• Process vehicles through your wash

• View car counts

• View historical information

• Track sales

• Print reports

• Troubleshoot problems if they occur

Many of the features you will find in the ICS Controller system were integrated at the
request of current car wash operators. We welcome your feedback and want to assure you
that ICS will always remain the best in the industry in car wash controller and management
systems.

Information in this manual is subject to change without notice. Companies, names and data used in examples within the manual are

fictitious 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 Innovative Control Systems, Inc.

Welcome 1

TUNNEL MASTER JR MANUAL

Table of Contents

Chapter Title Page

1 System Hardware and Installation

Relay Box
Mounting and Installation
Pulse / Proximity Switch Wiring
Gate (Electric Eye) Switch Wiring
Tire Switch Wiring
Entrance Management System Wiring
Roller Locator Wiring
Panic Stop Circuit Wiring
Anti Collision Wiring
Input Wiring Summary
Relay Box Jumper 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

2 Configuring the Wash

The Relay Box Keypad
Accessing a Password Protected Menu
Configure Wash Menu
Setting Date Time
Set Password
Wash Settings
Outputs
Services
Output Lists

3 Operating Procedures

Main Wash Menu
Wet Down Wash
Processing Vehicles
Viewing Service Counts
Shift Break

4
5
7

9
10
11
12
13
14
16
17
19
23
24
25
26

28
29
31
32
33
34
35
41
46
50
53
54
55
56
59
61

Table of Contents 2

TUNNEL MASTER JR MANUAL

Printing 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 Entry Keypads, Receipt &
Report Printer

Index 75

72
73
74

Table of Contents 3

Overview

Introduction

In this chapter

TUNNEL MASTER JR MANUAL

Chapter 1

System Hardware and Installation

This chapter provides a brief description of the hardware components
and their function. The Tunnel Master 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 in material, workmanship and
operating failure from normal use.

This chapter covers the following topics:

Topic See Page

The Relay Box 5
The Entrance Keypad 17
The Report / Receipt Printer (Optional) 25

System Hardware 4

Introduction

Exterior
picture

TUNNEL MASTER JR MANUAL

The Relay Box

The Relay Box is the control center for “firing” the various outputs or
services in the wash tunnel, i.e., Soap foamer, Reclaim motor, etc. The
Tunnel Master Jr. Controller relay box provides for automatic, computer
controlled or manual firing of the outputs. The relay box can control up
to 24 outputs.

24 toggle
switches

Each switch controls the operation of one output or service. The switch
has three positions:

• UP = Manual Override- Will manually turn on output. (This feature

can be “turned off” if desired)

• MIDDLE = Output Off. The output will not “fire.”

• DOWN = Computer controlled on position (normal)-Computer turns

on output

System Hardware 5

Interior picture

Each relay has circuits to control both 24VAC and/or 110VAC
simultaneously so that a service sign as well as the service solenoid can be
operated from the same relay.

• Plug in relays for ease of serviceability

• Each relay has 2 fuses

• Built in spare fuses and fuse tester at the center bottom of the box

• Each relay can be programmed to “Flash” thus eliminating the need for

Termination points for Pulse, Gate, Tire and Panic

circuits

Plug in relays for ease of serviceability
Each relay has two fuses (24VAC & 110VAC)

TUNNEL MASTER JR MANUAL

The Relay Box

field installed flashing relays for signs.

Built in spare fuses and fuse tester at the center
bottom of the box

24vac Transformer is for power
to the OEM circuit board ONLY.
Do not power any other devices
from this transformer!

Com Wire contacts for Entrance
Keypad, and Optional Report
Printer

System Hardware 6

TUNNEL MASTER JR MANUAL

The Relay Box Installation

Mounting and
Installation

Relay Box Mounting

• All site wiring must be performed be a licensed electrician that must comply with all

local and national codes.

• The relay box must be securely mounted to the wall in the equipment room of the car

wash. The relay box is designed to be located in a dry, non-corrosive environment.

• The relay box must be located so that conduit connections can be easily made, and the

relays can be readily accessed.

Relay Box Wiring

• Install one approved 3/4” conduit from the Relay Box to the Entrance Keypad box

located near the front of the wash tunnel. All conduit runs should meet all local and
national codes. Conduits shall be properly connected and securely fastened to the boxes
with Listed conduit hubs, and should be tightened to the torque specs of the
manufacturer. Over torqueing may cause enclosure breakage.

• Electrician must provide a dedicated 110vac circuit 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
adjacent to the terminal block. It is labeled with the universal ground symbol.
Terminations for the shielded cable should be torqued to 35 pound-inches.

• Electrician must supply a separate 24vac and 120vac circuit to the common (C) side of

the upper and lower termination points of each relay respectively, then loop the
commons together to each relay. This power is to “fire” the solenoids and equipment.

• A separation of 110vac and 24vac shall be maintained for all field-wiring circuits. All

24vac circuits must be supplied by a class 2 transformer.

• Tighten all wires on the circuit board in the relay box to 20 pound-inches (2.3 n-m.)

Overtorquing may cause enclosure breakage.

• Relays in the relay box are double pole with independent commons so that each relay

can have two circuits running through it. Commons are independent to provide a power
source to switch two devices through either the normally open or normally closed
circuits.

• Relays circuits should be supplied with no greater than 120vac 15amp.

This 120vac MUST BE A SEPARATE circuit from the dedicated 110vac circuit
terminated in the lower right corner of the OEM Relay Box.

The following instructions will provide detail information on proper
mounting and installation of the Entrance Keypad (See Appendix A for
equipment layout. options.)

System Hardware 7

TUNNEL MASTER JR MANUAL

The Relay Box Installation

Relay Box Wiring

• A 6.3 amp 250v fuse protects each relay. Four spare fuses along with LED fuse test

indicators are located at the bottom of the relay board. (Fuses should not be replaced
with any other device.)

• Another approved, ¾” conduit needs to be run to your motor control center to the Relay

Box and will contain the low voltage wires for clock (Pulse), gate (Entrance switch) and
Tire switch 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 marked PROX PWR,

CLK SINK, and PROX GND. (See Pulse switch wiring diagrams)

• Gate inputs and Tire inputs require a constant 24vac neutral supplied from a class 2

transformer. The hot signal would be terminated to the normally open pole of the
electric eye (gate) switch. (See wiring diagrams for Gate Switch and Tire Switch)

• Panic circuit inputs requires a constant 24vac neutral supplied through the stop/start

circuit. (See wiring diagrams for Panic Circuit options)

System Hardware 8

Pulse Switch
Wire Diagram

Important!

TUNNEL MASTER JR MANUAL

Pulse/Proximity Switch Wiring

The following diagram shows how to wire the pulse / proximity switch
into the Relay Box.

The pulse switch is a critical input for the OEM Controller. It signals
the system that the conveyor is moving and is the measuring device
from which the system knows when to turn equipment devices on and
off. See wash equipment vendor for location of the switch.

The OEM Controller is designed to accept all commonly used
pulse/proximity switches. 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 defined as a "Sourcing."(PNP) If it is
determined that this type of proximity switch is being used there are
two jumpers located just below the "CLK SINK" and "CLK SRCE"
contacts (JP1) & (JP2). These jumpers must be moved to the SOURCE
jumper position. Some pulse switches vary in the wire color. You
should check the pulse / proximity switch manual for proper color
codes.

Relay Box

2-Wire Pulse Switch with

Normally Open Contact

N.O.

Com

Smart Relay Box

3-Wire Proximity Switch

Sinking (NPN)

GND +12V

Used when connecting standard “Push Button” entry box

SIGNAL

System Hardware 9

Gate Switch
Wire Diagram

Important!

TUNNEL MASTER JR MANUAL

Gate (Electric Eye) Switch Wiring

The following diagram shows how to wire the Gate (electric eye)
switch into the Relay Box.

The "Gate" switch is the second critical input device to the OEM Relay
Box. It is usually an electric eye system or some type of vehicle
position detector located just before 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 piece of equipment.

This diagram to the Smart Relay Box starts at the control relay for the
sensing device being used. See the wash equipment provider for
location of this relay.

“

24vac Power Source

(Supplied by Other)

OEM Relay Box

Smart Relay Box

Relay Box

”

NeutralHot

Gate

-

Gate

+

N.O.Common

System Hardware 10

Electric Eye or Other

Sensing Device Relay

Tire Switch
Wire Diagram

Important!

24vac Power Source

(Supplied by Other)

TUNNEL MASTER JR MANUAL

Tire Switch Wiring

The following diagram shows how to wire the Tire switch into the
Relay Box.

This circuit is used if the 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 equipment. In order for this to work properly, the tire
switch should be located in line with the gate switch.

Smart Relay Box

NeutralHot

Tire -

N.O.Common

Relay Box

Tire +

System Hardware 11

EMS Treadle
Wiring Diagram

Important Note:

TUNNEL MASTER JR MANUAL

Entrance Management System Wiring

The following diagram shows how to wire the treadle switch for the
EMS into the Relay Box.

This circuit is used if the customer has purchased a treadle switch from
the equipment vendor. The Entrance Management System in the
Tunnel Master Junior allows a roller to be fired 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 signals
within 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. Once it sees the second signal, the TMJ will fire an
optional sign relay followed by a roller relay. The amount of time
between the sign firing and the roller is called the “Entrance
Management Delay” in the Wash Settings.

System Hardware 12

Roller Locator
Wire Diagram

Important Note:

TUNNEL MASTER JR MANUAL

Roller Locator Wiring

The following diagram shows how to wire the Roller Locator into the
Relay Box.

You can add a roller locator to the TMJ to keep your rollers from
jamming your conveyor. In order to do this a roller locator switch must
be installed in on your conveyor to signal the presence of a roller.
When a roller locator is used, 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 trailing edge of the signal either a normally open or normally closed
switch can be used.

To set this up two things need to be done.

1. 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 be in a position
where it is safe for the roller forks to come up.

2. Turn the roller locator function on in Wash Settings

System Hardware 13

Panic Stop
Circuit Diagram

Important!

TUNNEL MASTER JR MANUAL

Panic Stop Circuit Wiring

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

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

System Hardware 14

TUNNEL MASTER JR MANUAL

System Hardware 15

Anti Collision Wiring
Diagram

Important!

TUNNEL MASTER JR MANUAL

Anti Collision

The following diagram shows how to wire an anti collision
system into the Tunnel Master Jr.

The anti-collision on the Tunnel Master Jr. is a function to
help prevent cars from running into each other at the exit
end of the tunnel. In order for this to work you need an anti­collision device mounted in the tunnel at the spot 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 through some sort of
sensing device. The second variable is the Anti-collision
start time in wash settings on the 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 sensing
device is cleared. The system must also have a panic circuit
wired in for this function to be able to restart the conveyor.
(See the TMJ conveyor enable circuit drawing )

System Hardware 16

Tunnel Master Junior Input Wiring Summary

Input Wiring
Summary

TUNNEL MASTER JR MANUAL

The following diagram shows where all of the TMJ inputs get wired
into.

System Hardware 17

Jumper Settings

Relay Box Circuit
Board

(SW1) Circuit
Board Reset
Button

TUNNEL MASTER JR MANUAL

The Relay Box Jumper Settings

The following picture and table will explain the location and
purpose of the various jumpers on the Relay Box circuit board.

The following picture shows the Relay Box door circuit board and
location of the various jumpers, switches and controls.

Contrast Control
for front of box
LED display

JP6

JP2

JP5

JP4

JP3

JP8

JP9

Jumper Function

These are the jumper functions and their settings

Jumper Setting Function

J1 N/A
J2 ON
J3 485

Does not exist
BIAS High (+) set ON for the Main Relay box only.
3 position jumper should be on 2 pins to select 485 Communication
(UP)

J4 485

3 position jumper should be on 2 pins to select 485 Communication
(UP)

J5 ON

Transmit terminating resister. 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.

Dip Switch

JP7

JP10

JP11

System Hardware 18

TUNNEL MASTER JR MANUAL

J6 485

J7 OFF
J8 ON

J9 ON
J10 ON
J11 ON

3 position jumper should be on 2 pins to select 485 Communication
(Left)
Receive terminating resister.
Network Interface Chassis Ground Jumper
Network Interface Signal Ground Jumper
BIAS Low (-) set ON for the Main Relay box only.
ON = Enables, OFF = Disables manual override switches on relay
box,

System Hardware 19

Dip Switch Settings

Helpful Tips ☺

Relay Box Dip
Switch

TUNNEL MASTER JR MANUAL

The Relay Box Dip Switch Settings

The following picture and table will show the Relay Box Dip
switch and the various settings that may be used.

For location of the Dipswitch refer to the previous Relay Box
picture on page 14. The “ON” position is always up. A 24 Output
Relay Box will ship as ADDR1. If you were to add a second
Relay Box to the system, it should be addressed as ADDR9.

The following picture shows the Relay Box door Dip switch.

Switch Normal
Setting/Function

These are the dipswitch settings for normal operations.

Switch Setting Function

1 OFF Address setting:
2 OFF Address setting
3 OFF Address setting
4 OFF Address Setting

5 OFF Baud Rate: OFF = 9600 ON = 38,400
6 OFF Up position allows access to Initialization Menu options
7 OFF Pulse Enhancement
8 OFF Pulse Enhancement

System Hardware 20

1, 2, 3, 4 OFF
1 ON, 2, 3, 4 OFF
1 ON, 2, 3 OFF, 4 ON
1 & 3 ON, 2 & 4 OFF
1 ON, 2 OFF, 3, 4 ON

7 & 8 OFF
7 OFF, 8 ON
7 ON, 8 OFF
7 & 8 ON

= Address 1
= Address 9
= Address 10
= Address 11
= Address 12

Normal
2 Times
4 Times
8 Times

Introduction

Diagram

$ Button when
pressed, will print
a receipt if receipt
printer is attached

Arrow button when
pressed will start a
new shift.

Car button is the
(ROLLER) button

TUNNEL MASTER JR MANUAL

The Entrance Keypad

The Entrance Keypad is the service / output station at the front of the
car wash.

• Services sold to the customer are entered into the Entrance Keypad

• Vehicles are processed at the front of the wash with Entrance

Keypad.

• Some equipment diagnostics occur at the Entrance Keypad.

This is a picture of the Entrance Keypad.

Power indicator light
when lit, indicates
power to Entrance
Keypad

Data indicator light
when lit indicates data
being sent from OEM
Relay Box to the
Entrance Keypad.
(Used for
troubleshooting)

Logic Light, indicates
communications active
between Relay Box and
Entrance Keypad

Alpha buttons are all
programmable and
used for entering
services

AC Button when
pressed, clears all
services previously set

Note

In order to utilize the full functionality of the Entrance Keypad it is
very important that the electrician adhere to the wiring instructions
provided with the Relay Box.

System Hardware 21

Button
Function

TUNNEL MASTER JR MANUAL

The Entrance Keypad

These are the button functions for the Entrance Keypad.

Button Function

When pressed prints a receipt when optional
receipt printer is attached.

|$|

When pressed the current shift will close and a

⇑

Numeric buttons (1-16) used to program

3

new shift started.

services into system prior to processing vehicle.

Note

Roller button when pressed will activate the

roller relay.

AC (All Clear) button when pressed will clear

all previously entered services. To clear a

AC

All buttons with the exception of the AC button have red indicator
lights in the upper left corner of the button. These red indicators will
light after the button is pressed and stay lit until the vehicle has started
through the gate switch and reached minimum car length.

button pushed in error, simply push the button
again and the LED will go out.

System Hardware 22

TUNNEL MASTER JR MANUAL

The Entrance Keypad Installation

Mounting and
Installation

Entrance Keypad Mounting

• The Entrance Keypad should be mounted securely to the wall of the car wash, in the

entrance to the tunnel, at approximately chest height.

• The keypad is a Type 3 enclosure, which means it is a watertight enclosure, but should

not be mounted where it is constantly inundated with water.

• The keypad should be mounted away from corrosive chemicals.

Entrance Keypad Wiring

• Locate conduit that was run from 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. Overtorquing may cause enclosure
breakage.

• The conduit will contain the 24vac and Communications cable and should enter the

opening in the bottom of the keypad enclosure.

• Electrician must run 3 - 18 AWG wires, or cable (supplied by customer) through the

3/4” conduit above from the OEM relay box to the Entrance Keypad.

Keypad Connectors

The following instructions will provide detail information on
proper mounting and installation of the Entrance Keypad

The following picture shows the connection points for the various
components.

Optional Display
screen termination
points

Optional Receipt
printer termination
points

System Hardware 23

Communication wire
termination points.
You can use either
contact block. The
other would be to serial
in a second Keypad.

24vac termination
block

TUNNEL MASTER JR MANUAL

The Entrance Keypad Installation

Entrance Keypad Wiring

• There is a terminal block (POWER), located on the keypad circuit board labeled with

24H, 24L and GND, for Hot, Low and Ground, respectfully. Terminations for the 3 –
18AWG wires should be torqued to 20 pound-inches (2.3 n-m.) Overtorquing may
cause enclosure breakage.

• Some OEM Relay boxes may be equipped with a second 24vac transformer, which is to

be used to power the Entrance Keypad. If this second transformer is present the 24vac
terminations must be made as follows from the separate transformer, if there 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 corner of the OEM Relay Box

• Electrician must run a single-twisted pair, 24AWG shielded com cable (can be

purchased from ICS) through the above 3/4” conduit from the Relay Box to the
Entrance Keypad.

• There is a terminal block (NETWORK 485), located on the keypad circuit board 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 cause enclosure breakage.

• Com cable terminations must be made as follows:

Relay Box Entrance Keypad

(either connector) (either connector)

TX+ DT+
TX- DT-
GND GND

System Hardware 24

TUNNEL MASTER JR MANUAL

The Entrance Keypad Installation

Second Keypad
Mounting and
Installation

Second Entrance Keypad Mounting

• The second Entrance Keypad should be mounted securely to the wall of the car wash,

directly next to the first Entrance Keypad in the entrance to the tunnel.

• The keypad is a Type 3 enclosure, which means it is a watertight enclosure, but should

not be mounted where it is constantly inundated with water.

• The keypad should be mounted away from corrosive chemicals.

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 shall be properly connected and securely
fastened 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 the torque specs of the manufacturer. Overtoquing may cause enclosure
breakage.

• The conduit will contain the 24vac and Communications cable and should enter the

opening in the bottom of the keypad enclosure.

• Electrician must run 3 - 18 AWG wires, or cable (supplied by customer) through the

3/4” conduit above from the first Entrance Keypad to the second Entrance Keypad.

• There are terminal blocks (POWER), located on each of the keypad circuit boards

labeled with 24H, 24L and GND, for Hot, Low and Ground, respectfully. Terminations
for the 3 – 16AWG wires should be torqued to 20 pound-inches (2.3 n-m.)
Overtorquing may cause enclosure breakage.

• 24vac terminations must be made as follows:

First Entrance Keypad Second Entrance Keypad

24H 24H
24L 24L
GND GND

• Electrician must run a single-twisted pair, 24AWG shielded COM cable (can be

purchased from ICS) through the above 3/4” conduit from the first Entrance Keypad to
the second Entrance Keypad.

The following instructions will provide detail information on
proper mounting and installation of the optional second Entrance
Keypad

System Hardware 25

TUNNEL MASTER JR MANUAL

The Entrance Keypad Installation

Second Entrance Keypad Wiring

• There is a terminal block (NETWORK 485), located on each of the keypad 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 pound­inches (2.3 n-m.) Overtorquing may cause enclosure breakage.

• Com cable terminations must be made as follows:

First Entrance Keypad Second Entrance Keypad

(Either connector) (Either connector)

DT+ DT+
DT- DT­GND GND

System Hardware 26

Jumper Settings

Keypad Circuit
Board

JP4

TUNNEL MASTER JR MANUAL

The Entrance Keypad Jumper Settings

The following picture and table will explain the location and
purpose of the various jumpers on the Entrance Keypad circuit
board.

The following picture shows the Entrance Keypad circuit board
and location of the various jumpers

JP6

JP5

JP3

JP1

Jumper Setting/
Function

JP7

(SW1) Circuit
Board Reset
button

Dip switch

JP2

These are the 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 address 6.

Jumper Setting Function

J1 ON Reserved Jumper; ALWAYS ON
J2 ON Reserved Jumper; ALWAYS ON
J3 DOWN E-Prom Chip Enable; Jumper Down next to “CE”
J4 ON Ground Jumper
J5 OFF Biasing Resister High (+)
J6 OFF Biasing Resister Low (-)
J7 ON Terminating Resister. Set to ON if it is the first or

last device in the network.

System Hardware 27

The Entrance Keypad Dip Switch Settings

Dip Switch Settings

Helpful Tips ☺

Entrance Keypad
Dip Switch

TUNNEL MASTER JR MANUAL

The following picture and table will show the Entrance Keypad
Dip switch and the various settings that may be used.

For location of the Dipswitch refer to the 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.

Switch Normal
Setting/Function

These are the dipswitch settings for normal operations.

Switch Setting Function

1 OFF Address setting:
2 OFF Address setting

3 OFF Baud Rate OFF = 9600 ON = 38,400
4 OFF Test Mode

System Hardware 28

1, 2 OFF
1 OFF, 2 ON
1 ON, 2 OFF
1, 2 ON

= Address 5
= Address 6
= Address 7
= Address 8

Introduction

Helpful Tip ☺

TUNNEL MASTER JR MANUAL

The Optional Report/Receipt Printer

The Epson TM-T811 thermal printer is utilized by the Tunnel Master Jr.
system for both the report and receipt printer. These printers can be
purchased as an option to the base system or purchased and added to the
system after initial installation.

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 Matrix printer, please be sure to check the
dipswitch settings of the printer. DSW1 dipswitch 3 should be the only
dipswitch set to ON all of the others should be off. The dipswitches are
located on the bottom of the printer. You will have to remove the small door
covering the dipswitches.

Exterior
picture

System Hardware 29

TUNNEL MASTER JR MANUAL

Report Printer Installation

Mounting and
Installation

Report Printer Mounting

• The report printer should be set on a shelf, which is securely mounted next to the Relay

Box.

• The Epson report printer is not watertight. It is designed to be located in a dry, non-

corrosive environment.

• The report printer must be located so that connections can be easily made, and the

printed reports can be readily accessed.

Report Printer Wiring

• Electrician must provide a dedicated 110vac circuit and outlet to power the report

printer. This should be on the same dedicated circuit as the Relay Box.

• Drill and provide access into the Relay Box using a Listed ½” water tight compression

connector for a ¼” cable. The connector should be tightened to the torque specs of the
manufacturer. Overtorquing may cause enclosure breakage.

• Insert the cable with the 25-pin RS-232 connector attached (supplied by ICS) into the

OEM Relay Box. Allow excess cable outside the Relay Box for easy access to the
backside of the report printer so that the RS-232 25-pin connector can be easily attached
and removed.

• Attach the cable to one of the two RS-232 ports in the Relay Box labeled Gnd, Rxd,

Txd and 5v as follows:

Black Gnd
White/Black Rxd
Black/White Txd

• Tighten all wires on the circuit board in the relay box to 20 pound-inches (2.3 n-m.)

Overtorquing may cause enclosure breakage.

• Connect the 110vac power supply (provided by ICS) to the dedicated 110vac outlet and

the report printer.

• Connect the 25-pin RS-232 connector to the back of the report printer.

The following instructions will provide detail information on
proper mounting and installation of the Report Printer.

System Hardware 30

TUNNEL MASTER JR MANUAL

Receipt Printer Installation

Mounting and
Installation

Receipt Printer Mounting

• The receipt printer should be set on a shelf, which is securely mounted near the

Entrance Keypad

• The Epson report printer is not watertight. It is designed to be located in a dry, non-

corrosive environment.

• The receipt printer must be located so that connections can be easily made, and the

printed receipts can be readily accessed.

Receipt Printer Wiring

• Electrician must provide a dedicated 110vac circuit and outlet to power the report

printer. This should be on the same dedicated circuit as the Relay Box, if possible.

• Drill and provide access into the Entrance Keypad using a Listed ½” water tight

compression connector for a ¼” cable. The connector should be tightened to the torque
specs of the manufacturer. Overtorquing may cause enclosure breakage.

• Insert the cable with the 25-pin RS-232 connector attached (supplied by ICS) into the

Entrance Keypad. Allow excess cable outside the Keypad for easy access to the
backside of the receipt printer so that the RS-232 25-pin connector can be easily
attached and removed.

• Attach the cable to connector labeled PTX, PRX and GND as follows:

Black Gnd
White/Black PRX
Black/White PTX

• Tighten all wires on the circuit board in the relay box to 20 pound-inches (2.3 n-m.)

Overtorquing may cause enclosure breakage.

• Connect the 110vac power supply (provided by ICS) to the dedicated 110vac outlet and

the report printer.

• Connect the 25-pin RS-232 connector to the back of the receipt printer.

The following instructions will provide detail information on
proper mounting and installation of the Receipt Printer.

System Hardware 31

Overview

Introduction

In this chapter

TUNNEL MASTER JR MANUAL

Chapter 2

Wash Configuration

This chapter will provide information on how to setup and configure
facility specific information and how to use some of the features of
your new Tunnel Master Jr. Car Wash Controller. The Tunnel Master
Jr. controller contains unique features usually found only in the high­end full service wash controller systems. Things such as the
copyrighted anti-theft software, integration with a Panic Stop circuit
and for quick morning wash checkouts our easy to use “Wetdown”
feature.

This chapter covers the following topics:

Topic See Page

The Relay Box Keypad 29
Accessing a Password Protected Menu 31
The Configure Wash Menu 32
Setting Date and Time 33
Wash Settings 35
Setting up Outputs 41
Setting up Services 46
Assigning Outputs to Services 50

Wash Configuration 32

Introduction

Picture

+5 Volt indicator light,
indicates power good
to input terminal

Logic Light, indicates
communications active
between Opto and
Input Terminal

Clock indicator light
When blinking, indicates
operation of pulse switch
on conveyor.

Gate switch indicator
light when on, indicates
gate switch (electric eye)
is on and sensing.

Tire switch indicator
light. When on,
indicates tire switch is
on and sensing.

TUNNEL MASTER JR MANUAL

The Relay Box Keypad

The Relay Box keypad is the primary place from which to program and
configure the wash tunnel. If your facility has two relay boxes, one of
them will serve as the primary input relay box. From this screen you
can:

• Setup and configure the wash tunnel outputs and services

• View car count and some sales information

• Print vehicle count and sales information, if optional report

printer is installed.

• Some equipment diagnostics occur at the OEM Relay Box

• Manually process cars and apply services.

This is a picture of the Keypad.

Panic condition indicator
light , When on, indicates
panic circuit is activated

Function buttons, (F1 –
F4) Used when
programming system.

Menu button. Used
when accessing menu
options.

Numeric keys.
Used when
entering data and
programming

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.

Wash Configuration 33

Button
Function

TUNNEL MASTER JR MANUAL

The Relay Box Entry Keypad

These are the button functions for the Relay Box Entry Keypad.

Button Function

F1 – F4

Numeric

1-9

Numeric

0

AC

Function buttons are used during the setup and
programming of the wash facility. During setup
options will be displayed at the bottom of the display
indicating which button to press for the option desired.
Options:
F1 = PREV allows user to return to previous screen
F2 = NEXT allows user to advance to the next screen
F3 = CLEAR allows user to clear existing entries
F4 = SAVE allows user to save new settings entered.
Numeric buttons are also used during programming as
well as entering passwords etc. When entering a
desired letter, press the corresponding numeric key to
select the desired number.

Example: When you wish to enter the letter “C” press
the number “1” key three times.

The “0” button has multiple functionality depending on
what is being programmed. In most menu options the
“0” button when pressed will allow for a space, a
decimal point or zero. When setting service or output
features where there is more than one option the “0”
button can be pressed to scroll through the various
options allowed for that setting.
The AC button clears all entries on the current screen

ENT

Menu

Display Lights

Wash Configuration 34

+5V DC

LOGIC

When pressed during programming allows user to
advance to the next option.
The Menu button is used when accessing various menu
options in your car wash controller. It is also used as
an “Escape” key to exit out of the current screen
display or to return to the previous menu.

This light should be lit at all times indicating that the
system has power.
This light should be blinking in a steady rapid beat
indicating that the system is sending and receiving
logic information within the system.

Introduction

Important!

Procedures

TUNNEL MASTER JR MANUAL

Accessing a Password Protected Menu

Once a password has been set into the system any access desired to the
menu options will require that the user enter the password that has been set
into the system.

For ease of setup in this manual it will be assumed that the user will have
entered the correct password to enter the main menu to setup and access
the system.

Follow these procedures to enter the system password.

Step Action Screen Displays

1 Press the Menu key from the

main screen display

2 Using the numeric keypad,

type in the first letter of the
password.

Example: For the letter “L”
press the “4” key three times

3 Wait until the cursor moves

to the next position

Warning: If you press ENT
after entering a letter, what
you have entered to that
point will be accepted as
your the password and you
will be returned to the main
screen display!

4 Repeat steps 3 & 4 until the

entire password is entered.

5

Press the “ENT” button to
accept the password.

ICS OEM Tunnel Controller 10:25:35 PM
VER 1 REV 5.11 04/15/2002
Password _ _ _ _ _ _
ADDR =1 CARS 0000

ICS OEM Tunnel Controller 10:25:35 PM
VER 1 REV 5.11 04/15/2002
Password * _ _ _ _ _
ADDR=1 CARS 0000

ICS OEM Tunnel Controller 10:25:35 PM
VER 1 REV 5.11 04/15/2002
Password * _ _ _ _ _
ADDR=1 CARS 0000

ICS OEM Tunnel Controller 10:25:35 PM
VER 1 REV 5.11 04/15/2002
Password ****_ _
ADDR=1 CARS 0000

[1] Shift Break [4] View Counts
[2] Wet Down Wash [5] Print Reports
[3] Configure Wash

Wash Configuration 35

Introduction

Menu
Options

TUNNEL MASTER JR MANUAL

Configure Wash Menu

Before any washes can be processed the user must configure the wash.
There are many items to be configured including the actual tunnel setup all
the way to setting up services. Each item must be configured accurately if
the wash is to operate properly

The following is a list of menu options in the Configure Wash menu and a
brief explanation of their function.

Item Menu Option Function

1 Services In the Services menu option the user will

define the various services and wash options
they will have at their car wash.

2 Outputs This option is where the user will setup what

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 available to sell.

4 Wash Settings Wash Settings allows the user to set the

various equipment settings that directly
relate to their particular equipment. This is
where the user will set many of the unique
feature of the Tunnel Master Jr. Tunnel
Controller

5 Set Date Time This option allows the user to set the date

and time the system will recognize.

6 Set Password This option allows you to setup a password

to restrict access to the menus on the relay

.

box

Note

This manual will take you through the process of setting up a car wash. It
will do this in the logical order for the setup, which may not necessarily be
the order in which the menu options appear on the screen.

Wash Configuration 36

Introduction

Procedures

TUNNEL MASTER JR MANUAL

Set Date Time

The first item to program is the correct date and time for the system to
recognize. This is menu option #3 in the Configure Wash menu. The time
will be important in that other programming options such as when to
automatically bump a shift will need the correct time set to accomplish the
process at the correct time of day.

Follow these procedures to set or change the correct date and time in the
system

Step Action Screen Displays

1 Press the numeric key “3”

from the Main Menu to
select Configure Wash

2 Press the numeric key “5” to

select Set Date Time

[1] Shift Break [4] View Counts
[2] Wet Down Wash [5] Print Reports
[3] Configure Wash

[1] Services [4] Wash Settings
[2] Outputs [5] Set Date Time
[3] Output List [6] Set Password

3 Using the numeric keys type

in the month.

4 Press the “ENT” key after

the correct selection is
made.

5 Repeat steps 3 & 4 to

correctly enter the day, year,
hour, minutes, seconds and

Set Date Time
Date: 04/_ _/_ _ _ _
Time: 10:25:35 AM
Press [Menu] to return

Set Date Time
Date: 04/_ _/_ _ _ _
Time: 10:25:35 AM
Press [Menu] to return

Set Date Time
Date: 04/15/2002
Time: 10:25:35 AM
Press [Menu] to return

weather it is AM or PM

6 Press the “MENU” key to

save your changes and

[1] Services [4] Wash Settings
[2] Outputs [5] Set Date Time
[3] Output List [6] Set Password

return to the Configure
Menu.

Wash Configuration 37

Introduction

Procedures

TUNNEL MASTER JR MANUAL

Set Password

The feature allows you to restrict access to the menus in Tunnel Master Jr.
System.

Follow these procedures to set or change the system password.

Step Action Screen Displays

1 Press the numeric key “3”

from the Main Menu to
select Configure Wash

2 Press the numeric key “6” to

select Set Password

[1] Shift Break [4] View Counts
[2] Wet Down Wash [5] Print Reports
[3] Configure Wash

[1] Services [4] Wash Settings
[2] Outputs [5] Set Date Time
[3] Output List [6] Set Password

3 It will then prompt you for

the new password.

4 Enter in your password and

press the ENT key to save
your changes and return to
the Configure Wash Menu.

New Password: _ _ _ _ _ _ _ _ _ _

New Password: ICS _ _ _ _ _ _ _

Wash Configuration 38

TUNNEL MASTER JR MANUAL

Wash Settings

Introduction

Menu Items
Function

The Wash Settings menu option is where important information about the
user’s specific car wash equipment is programmed. Important features
such as the anti-theft program and Wet Down option are set in this menu.

The following is a list of menu items within the Wash Settings menu
option and a brief explanation of their function.

Menu Item Function

Pulse Length Pulse length must be set and will affect the input for

Min and Max Car Length as well as Anti Bounce
settings. Enter “1” if the user wishes the system to
track start stop times in pulses. Enter the number of
inches of chain travel for one pulse if the user wishes to
set start stop times in inches.

Note: This measurement could also be in metric
calculations.

Min Car Length The length in inches or 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 anti­bounce value. This is part of the anti-theft features.

Note: If using inches, when an entry is made the system
will round off to the closest setting possible based on
the entry made.

Max Car Length The length in inches or the number of pulses of the

longest vehicle that will enter the car wash before a
violation is recorded. This is part of the anti-theft
feature.

Note: If using inches, when an entry is made the system
will round off to the closest setting possible based on
the entry made.

Anti Bounce The length in inches or the number of pulses that the

system still counts a vehicle if the sensor drops out as
car passes the gate switch for less than anti-bounce
value and comes back on. Value MUST be less than
value set for Min Car Length.

Note: If using inches, when an entry is made the system
will round off to the closest setting possible based on
the entry made.

Wash Configuration 39

TUNNEL MASTER JR MANUAL

Wash Settings (Continued)

Auto Pulse
Period

Auto Pulse Enter Y for yes, N for no if the user wishes the system

Invert Gate Enter Y for yes, N for no, allows operator to decide if

Auto Gate Delay Enter the length in inches or pulses of estimated chain

Auto Gate Enter Y for yes, N for no. This feature is used as a

Roller Control Enter Y for yes, N for no if one of the outputs will fire

Entrance
Management
Entrance Mgmt
Delay

Roller Locator Enter Y for yes, N for no. When this option is set to

Roller Interlock Enter Y for yes, N for no. When this option is set to

Auto Roller Enter Y for yes, N for no. When this option is set to

Panic Stop

This is the rate in which you want the conveyor
to run when in Auto Pulse.

value to 0 when the conveyor is running. Doing this
will automatically calibrate this setting based on
your conveyor speed. If you change conveyor
speeds, you should reset this.

You should set this

to simulate a pulse in the event of pulse switch failure.

Note: This feature will activate as soon as “Y” is
entered and the user hits save.

logo switch is wired low or high. (Will vehicle break
continuous circuit or complete a circuit?)

travel, after a roller button is activated, before a vehicle
would normally activate the gate switch. This value
must be greater than 0.

back up for 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.

the roller solenoid.
Enter Y for yes, N for no if you have a treadle switch
wired into Input 10.
Optional setting to be used with the Entrance
Management System. This value is the number of
seconds you want the roller output to delay before
firing.

yes, the system will wait to fire the Roller Output until
the trailing edge of a signal is detected from Input 9.

yes, the system will not allow a roller to be fired
without a service being selected. This value should be
set to N if using the TMJ Interface.

yes, as soon as you select a base service on a non­stacking system, a roller will fire.
Enter Y for yes if you have the panic stop wired into
the system, N for no if a Panic Stop is not installed.

Wash Configuration 40

TUNNEL MASTER JR MANUAL

Anti Collision This is going to be the distance from first gate input to

where you want the anti collision feature to trigger.

See the page 14 for the anti-collision diagram and for
a detailed explanation. (Must have Panic Enable
Circuit wired in.)

Auto Stop Period Enter the number of seconds after the last car you want

the system to automatically shut the conveyor off. You

must have an Auto Stop output wired and setup in
order for this feature to work.

Wet Down
Period

Flash On In 100 mili-seconds increments how long the relay will

Flash Off

Shift This displays the shift number that the system is

Auto Shift Enter Y for yes, N for no. If you set this option to Y,

Tax Rate 1 % The percentage rate for the first tax rate charge.
Tax Rate 2 % The percentage rate for the second tax rate charge.
Stacking Enter Y for yes or N for no. If you set this option to Y,

Input Device This is set K for keypad, P for push button or C for

Push Button
Rows

Push Button
Cols

Console Debug This is a debug utility that ICS may use to track system

Enter the number of seconds you would like to have
the wash equipment turned on for the wet down
process. A wet down will fire all of the outputs that
have Y for the wet down option.

flash on. This is what the system looks at when you set
the output flash to Y.
In 100 mili-seconds increments how long the relay will
flash off. This is what the system looks at when you set
the output flash to Y.

currently on. You cannot change this setting.

the system will automatically close the shift at
midnight. This option should be set to Y if you are
using the TMJ Interface.

the system will start stacking. This option should be
set to N if using the TMJ Interface.

Computer / Controller. This is used to interface with
Tunnel Master Sr.
If a push button entry station is being used, enter the
number of rows, going across, of buttons on the
station. This will tell the system what inputs to accept.

If you do not have a push button station, this option is
disregarded.

If a push button entry station is being used, enter the
number of columns, going down, of buttons on the
station. If you do not have a push button station, this
option is disregarded.

activity. This should be set to N if you are using the
TMJ Interface.

Wash Configuration 41

TUNNEL MASTER JR MANUAL

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 information desired to display on the second line

on the top of reports and receipts. This is usually
company information.

Header 3 Enter information desired to display on the third line

on the top of reports and receipts. This is usually
company information.

Header 4 Enter information desired to display on the fourth line

on the top of reports and receipts. This is usually
company information.

Footer 1 Enter information desired to display on the first line on

the bottom of receipts. This is usually a message to the
customer.

Footer 2 Enter information desired to display on the second line

on the bottom of receipts. This is usually a message to

the customer.

Footer 3 Enter information desired to display on the third line

on the bottom of receipts. This is usually a message to
the customer.

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

yes, the daily car count will display on the main
display on the relay box.

Car Count Displays the number of cars for the current shift. This

is reset when you bump a shift.

Invalid Count This is the number of times in the current shift that the

gate input started to sense a car, but it did not measure
up to the Min Car Length. This count is reset when a
shift is bumped.

Violation Count This is the number of times in the current shift that the

gate sensed a car longer than the Max Car Length.
This count is reset when a shift is bumped.

Cleared Count This is the number of times in the current shift that a

service wash cleared. This count is reset when a shift
is bumped.

Duplicate Count This is the number of times in the current shift that a

duplicate receipt was printed. This count is reset when
a shift is bumped.

Relay Address2 This is the address of the Relay box. The dipswitches

determine this. If this is a 24 output system, set this to
“0”. If it is a 48 output system, set this to “9”.

Wash Configuration 42

TUNNEL MASTER JR MANUAL

Key Pad 1
Address

Key Pad 2
Address

Report Address This is the address in which the report printer is

Receipt Address This is the address in which the receipt printer is

Net Error Count This displays the number of network errors that have

This is the address of the first Key Pad. If you are
using a push button station, set this to “0”. By default
the keypad is set to “5”. If you are using multiple
keypads consult the dipswitch settings on the keypad
for the proper address.
This is the address of the second Key Pad. The
address of the keypad is based on the dipswitch
settings on the keypad.

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 the reports will
print out.

hooked up to. If the receipt printer is hooked up to the
main relay box, then set this to “0”. If the receipt
printer is hooked up to the keypad, set this option to
“5”. This is the printer where all of the reports will
print out.

occurred since the system was setup. This is used for
troubleshooting purposes only and is not changeable.

Wash Configuration 43

Menu Item

Function

TUNNEL MASTER JR MANUAL

Wash Settings

Menu items and an explanation of their function.

Step Action Screen Displays

1 Press the [MENU] button

from the main screen display

[1] Shift Break [4] View Counts
[2] Wet Down Wash [5] Print Reports
[3] Configure Wash

2 Press the numeric key “3” to

select the Configure Wash
menu option.

3 Press the numeric key “4” to

select the Wash Settings
menu option.

4 Using the numeric key pad

enter the desired setting for
Pulse Length

Note: Review button
functions on page 31.

5 Press the “F4” button on the

display pad to accept and
save the entry.

6 Press the “F2” button to

advance to the next setting
to enter

7 Repeat steps 4 – 6 until all

settings have been
programmed.

8 Press the [MENU] button to

return to the previous menu
screen

[1] Services [4] Wash Settings
[2] Outputs [5] Set Date Time
[3] Outputs Lists [6] Set Password

PulseLength _ _ _ _ _ _ _ _ _ _

F1=PREV F2=NEXT F3=RESET F4=SAVE

PulseLength 7.75_ _ _ _ _ _

F1=PREV F2=NEXT F3=RESET F4=SAVE

PulseLength 7.75_ _ _ _ _ _

F1=PREV F2=NEXT F3=RESET F4=SAVE

MinCarLength _ _ _ _ _ _ _ _ _ _

F1=PREV F2=NEXT F3=RESET F4=SAVE

MaxCarLength _ _ _ _ _ _ _ _ _ _

F1=PREV F2=NEXT F3=RESET F4=SAVE
[1] Services [4] Wash Settings

[2] Outputs [5] Set Date Time
[3] Outputs Lists [6] Set Password

Wash Configuration 44

Introduction

Menu Items
Function

TUNNEL MASTER JR MANUAL

Outputs

The Outputs menu option is where the user will initially setup and later as
needed edit the wash relays that will be activate for the various was
equipment. The basic Tunnel Master Jr. Relay Box allows for up to 24
Outputs. There is an option to add an additional Relay Box that will
provide for an additional 24 Outputs for a total maximum of 48.

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 corresponding to the relay switch

on the outside of the relay box. They are numbered 1-12
down the left side and 13-24 down the right.

Name The name of the specific equipment controlled by this

relay, i.e., Soap Foamer, etc.

Start Enter the number of pulses or inches, depending on the

setup choice in Wash Settings, for how far past the gate
switch (electric eye) the piece of equipment should turn on.

Wash Configuration 45

TUNNEL MASTER JR MANUAL

Type Use the “0” button to advance to select the option desired.

M = Mandatory, relay will activate for any service sold
that is set as a Base.
S = Selective, relay will activate only when a service set as
an Extra Service is sold along with a Base service.
D = Deselective, relay will NOT activate when a service
with this output is selected.
C = Conveyor, relay is activating the motor starter solenoid
for the conveyor motor when a Panic circuit is wired to the
designated relay.
R = Roller, relay activates the roller up solenoid. Start
time entered on Roller output will be how long the roller
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 is known as an up down up.
A = Auto Stop, relay is tied to a stop circuit for shutting
down the car wash after the last vehicle exits the wash or
there is no wash activity. In order for this to work, you
must set the Auto Stop Period in the Wash Settings.
O = This output is used to start the conveyor once you
have a base service selected. NOTE: YOU MUST

HAVE A HORN RELAY SETUP WITH A START
TIME IN ORDER FOR THIS RELAY TO FIRE.
H = This output will fire your Horn. The start time for this

output is how long, in seconds, that the horn will blow for.
The extend time is how long, in seconds, the system will
delay starting the conveyor.

Wash Configuration 46

TUNNEL MASTER JR MANUAL

Outputs

Menu Items
Function

Continuation of a list of menu items within the Outputs menu and a brief
explanation of their function.

Menu Item Function

Part Use the “0” button to advance to the desired choice for

what part of the car this piece of equipment is to turn on
for.

AC = All of the Car
FH = Front Half of the vehicle
FB = Front Bumper only
RH = Rear Half of vehicle
RB = Rear Bumper only
TA = Activate from a tire switch for tires or wheels. On A

Tire Output, The Start Time Is Where In The Tunnel The
Equipment Is And The Extend Time Is How Long The
Output Will Stay On For.
ES = Entrance sign, relay will activate after vehicle is
“Loaded” and shut off as vehicle reaches gate switch. An
entrance sign can only be a Selective output. An Entrance
Sign may not be a Mandatory 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 reached.

Flash Enter Y for yes, or N for no if the relay is to flash on and

off when it is activated.

Extend Enter the number of pulses or inches, depending on the

setup choice in Wash Settings, for how far past the actual
length of the vehicle the piece of equipment should stay
on.

Note: Many outputs must be turned on early in order to be
“charged” up before the vehicle gets to it. The Extend
feature allows the user to keep the relay activated so that
the rear of the vehicle does not get missed.

Look Enter the number of pulses or inches for the system to look

back into the wash to see if there is another vehicle
approaching. If there is another vehicle within the setting
entered the system will leave that relay on to prevent
frequent stopping and starting of electric motors which
drives up utility charges.

Wash Configuration 47

TUNNEL MASTER JR MANUAL

Wet Enter Y for yes, or N for no if the relay should activate

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 were setup to
activate at Wet Down will turn on and stay on for the time
set in the Wash Setting menu option.

Wash Configuration 48

Menu Items
Function

TUNNEL MASTER JR MANUAL

Outputs

Continuation of a list of menu items within the Outputs menu and a brief
explanation of their function.

Menu Item Function

Panic Two setting here if there is a Panic circuit is wired to the

system.
The first, 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 a

Panic condition occurs.
For the second setting, Staggered Start time, enter “0” if
the output is to restart when the conveyor restarts, or enter
the number of seconds after the release of a Panic
condition the user wants the equipment to restart prior to
the conveyor restarting.

Wash Configuration 49

Procedures

TUNNEL MASTER JR MANUAL

Outputs

Follow these procedures to set or change the settings for the Outputs in the
Tunnel Master Jr. Controller program.

Step Action Screen Displays

1 Press the [MENU] button

from the main screen display

[1] Shift Break [4] View Counts
[2] Wet Down Wash [5] Print Reports
[3] Configure Wash

2 Press the numeric key “3” to

select the Configure Wash
menu option.

3 Press the numeric key “2” to

select the Outputs menu
option.

4 Using the numeric keypad

enter the desired number for
the output.

Note: Review button
functions on page 31.

5 Press the “ENT” button on

the display pad to advance
to the next setting.

6 Using the numeric buttons

enter in the name of the
Output.

7 Press the “ENT” button on

the display pad to advance
to the next setting.

8 Using the numeric buttons

enter the Start time in inches
or pulses depending on the
wash setting selection.

9 Press the “ENT” button on

the display pad to advance
to the next setting.

[1] Services [4] Wash Settings
[2] Outputs [5] Set Date Time
[3] Output Lists [6] Set Password

Output _ _ Name _ _ _ _ _ _ _ _ _ _
Start _ _ Type _ Part _ _ Flash _
Extend _ _ _ _ Look _ _ _ Wet _ Panic _ - _ _

F1=PREV F2=NEXT F3=ERASE F4=SAVE
Output 01 Name _ _ _ _ _ _ _ _ _ _

Start _ _ Type _ Part _ _ Flash _
Extend _ _ _ _ Look _ _ _ Wet _ Panic _ - _ _

F1=PREV F2=NEXT F3=ERASE F4=SAVE

Output 01 Name
Start _ _ Type _ Part _ _ Flash _
Extend _ _ _ _ Look _ _ _ Wet _ Panic _ - _ _

F1=PREV F2=NEXT F3=ERASE F4=SAVE
Output 01 Name Roller
Start _ _ Type _ Part _ _ Flash _
Extend _ _ _ _ Look _ _ _ Wet _ Panic _ - _ _

F1=PREV F2=NEXT F3=ERASE F4=SAVE
Output 01 Name Roller
Start _ _ Type _ Part _ _ Flash _
Extend _ _ _ _ Look _ _ _ Wet _ Panic _ - _ _

F1=PREV F2=NEXT F3=ERASE F4=SAVE
Output 01 Name Roller
Start 0084 Type _ Part _ _ Flash _
Extend _ _ _ _ Look _ _ _ Wet _ Panic _ - _ _

F1=PREV F2=NEXT F3=ERASE F4=SAVE

Output 01 Name Roller
Start 0084 Type _ Part _ _ Flash _
Extend _ _ _ _ Look _ _ _ Wet _ Panic _ - _ _

F1=PREV F2=NEXT F3=ERASE F4=SAVE

Wash Configuration 50

Procedures

TUNNEL MASTER JR MANUAL

Outputs

Follow these procedures to set or change the settings for the Outputs in the
OEM Controller program.

Step Action Screen Displays

10 Repeat steps 8 & 9 until the

settings for Type, Part,
Flash, Extend, Look and
Wet are completed.

Note: Review the settings
options on pages 41 – 43.

11 Press the “ENT” button on

the display pad to advance
to the Panic setting.

12 Using the “0” button on the

numeric keypad advance to
the desired setting, either
“Y” or “N” for no.

13 Press the “ENT” button on

the display pad to advance
to the second setting in the
Panic option.

14 Using the numeric keys on

the button pad enter the
number of seconds of delay
for this relay to turn on
before the conveyor will
restart.

Note: If you do not wish this
relay to stagger start enter
“0”

15 Press the “F4” button to

save the service.

16 Press the [MENU] button to

return to the previous menu
screen

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

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
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

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

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

Output _ _ Name _ _ _ _ _ _ _ _ _ _
Start _ _ Type _ Part _ _ Flash _
Extend _ _ _ _ Look _ _ _ Wet _ Panic _ - _ _

F1=PREV F2=NEXT F3=ERASE F4=SAVE
[1] Services [4] Wash Settings
[2] Outputs [5] Set Date Time
[3] Output Lists [6] Set Password

Wash Configuration 51

Introduction

Menu Items
Function

TUNNEL MASTER JR MANUAL

Services

The Services menu option is where the user will initially setup and edit the
wash services that will be available on the system. The basic controller
configuration allows for up to 16 services and the roller control as the 17th.
There is an option to add an additional entrance Keypad that will provide
for an additional 16 services for a total maximum of 32 services. YOU

MAY NOT MAKE CHANGES TO THE SERVICES WHILE IN A
SHIFT. THE CAR COUNT MUST BE 0. YOU MAY BUMP A
SHIFT AT THE KEYPAD OR THE RELAY BOX. (SEE PAGE 62)

The following is a list of 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 will be available
and their location on the Entrance Keypad. The numbers
represent a PLU # or Price Look Up for the system to refer
to when displaying and printing reports.

Name Use the numeric keys to enter the name of the service to be

programmed.

Price Use the numeric keys to enter the price for the service

being programmed.

Note: To enter a decimal point press the “0” button two
times.

Type Use the “0” button to advance to the desired type of

service.
B=Basic: The service will include all mandatory
outputs be activated for when sold.
E=Extra Service: Those services which are sold as add-ons
to a basic wash service, i.e., Polish Waxes

Wash Configuration 52

TUNNEL MASTER JR MANUAL

Rate Use the numeric buttons or 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 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 in the
wash settings menu.
2 = Tax Rate 2: The tax rate set in Tax Rate 2 in the
wash settings menu.
3 = Both 1 & 2: Both Tax Rate 1 & 2 will be applied to
the sale of the service.

Wash Configuration 53

Procedures

TUNNEL MASTER JR MANUAL

Services

Follow these procedures to set or change the Services in the Tunnel Master
Jr. Controller program.

Step Action Screen Displays

1 Press the [MENU] button

from the main screen display

[1] Shift Break [4] View Counts
[2] Wet Down Wash [5] Print Reports
[3] Configure Wash

2 Press the numeric key “3” to

select the Configure Wash
menu option.

3 Press the numeric key “1” to

select the Services menu
option.

4 Using the numeric keypad

enter the desired PLU# for
the service.

Note: Review button
functions on page 31.

5 Press the “ENT” button on

the display pad to advance
to the next setting.

6 Using the numeric buttons

enter in the name of the
service.

7 Press the “ENT” button on

the display pad to advance
to the next setting.

8 Using the numeric buttons

enter the price of the service.
Use the “0” button for a
decimal point.

9 Press the “ENT” button on

the display pad to advance
to the next setting.

[1] Services [4] Wash Settings
[2] Outputs [5] Set Date Time
[3] Output Lists [6] Set Password

Service _ _ Name
Price Type
Rate

F1=PREV F2=NEXT F3=ERASE F4=SAVE
Service 01 Name

Price Type
Rate

F1=PREV F2=NEXT F3=ERASE F4=SAVE

Service 01 Name _ _ _ _ _ _ _ _ _ _
Price Type
Rate

F1=PREV F2=NEXT F3=ERASE F4=SAVE
Service 01 Name GOLD WASH
Price Type
Rate

F1=PREV F2=NEXT F3=ERASE F4=SAVE
Service 01 Name GOLD WASH
Price _ _ _ _ _ Type
Rate

F1=PREV F2=NEXT F3=ERASE F4=SAVE
Service 01 Name GOLD WASH
Price 9.99 Type
Rate

F1=PREV F2=NEXT F3=ERASE F4=SAVE

Service 01 Name GOLD WASH
Price 9.99 Type _
Rate

F1=PREV F2=NEXT F3=ERASE F4=SAVE

Wash Configuration 54

Procedures

TUNNEL MASTER JR MANUAL

Services

Follow these procedures to set or change the Services in the Tunnel Master
Jr. Controller program.

Step Action Screen Displays

10 Using the numeric button

“0” scroll to the desired
“Type” of service, B, for
Basic, E for Extra Service.

11 Press the “ENT” button on

the display pad to advance
to the next setting.

12 Using the numeric buttons

enter the desired tax rate
option, 0, 1, 2, or 3.

13 Press the “F4” button to

save the service.

14 Press the [MENU] button to

return to the previous menu
screen

Service 01 Name GOLD WASH
Price 9.99 Type B
Rate

F1=PREV F2=NEXT F3=ERASE F4=SAVE

Service 01 Name GOLD WASH
Price 9.99 Type B
Rate _

F1=PREV F2=NEXT F3=ERASE F4=SAVE
Service 01 Name GOLD WASH
Price 9.99 Type B
Rate 1

F1=PREV F2=NEXT F3=ERASE F4=SAVE
Service 01 Name GOLD WASH
Price 9.99 Type B
Rate 1

F1=PREV F2=NEXT F3=ERASE F4=SAVE
[1] Services [4] Wash Settings
[2] Outputs [5] Set Date Time
[3] Output Lists [6] Set Password

Wash Configuration 55

Introduction

Menu Items
Function

TUNNEL MASTER JR MANUAL

Output Lists

The Output Lists menu option is where the user will initially setup, and
later as needed, edit what outputs will activate for each of the services they
offer. This feature is simply telling the system what outputs will fire for
each service. Only services, which will include outputs that have been
programmed as, Selective, or Deselective, have to be setup in the Output
Lists. Any services setup as a BASE service will automatically have all
Mandatory outputs activated. IT IS NOT NECESSARY TO LIST THE
MANDATORY 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.

The following is a list of menu items within the Outputs menu and a brief
explanation of their function.

Menu Item Function

Service Enter the PLU # of the service the user wants to setup in

the Output Lists

Output Enter in each output number, which the user wishes to

have activated with this service. After each comma, enter
the two-digit number corresponding to the Output setup in
the Outputs menu option.

Important: Only Selective and Deselective outputs need to
be entered. Mandatory outputs will automatically be
activated anytime a Service setup as a Base service is
“loaded” into the Entrance Keypad.

Wash Configuration 56

Procedures

TUNNEL MASTER JR MANUAL

Output Lists

Follow these procedures to set or change the Outputs that will be activated
for the various service options.

Step Action Screen Displays

1 Press the [MENU] button

from the main screen display

[1] Shift Break [4] View Counts
[2] Wet Down Wash [5] Print Reports
[3] Configure Wash

2 Press the numeric key “4” to

select the Configure Wash
menu option.

3 Press the numeric key “3” to

select the Output Lists
menu option.

4 Using the numeric keypad

enter the PLU# of the
service to be programmed.

5 Press the “ENT” button on

the display pad to advance
to the next setting.

6 Using the numeric buttons

enter in the number
corresponding to the
Selective or Deselective
output the user wishes to
have activated when this
service is processed.

7 Press the “ENT” button on

the display pad to advance
to the next setting.

8 Repeat steps 6 & 7 until all

desired outputs have been
programmed.

[1] Service [4] Wash Settings
[2] Outputs [5] Set Date Time
[3] Output Lists [6] Set Password

Service _ _
Outputs , , , , , , ,
, , , , , , ;

Service 03
Outputs , , , , , , ,
, , , , , , ;

Service 03
Outputs _ _, , , , , , ,
, , , , , , ;

Service 03
Outputs 05, , , , , , ,
, , , , , , ;

Service 03
Outputs 05, _ _ , , , , , ,
, , , , , , ;

Service 03
Outputs 05, 06 , , , , , ,
, , , , , , ;

Wash Configuration 57

Procedures

TUNNEL MASTER JR MANUAL

Output Lists

Procedures to assign outputs to services continued.

Step Action Screen Displays

9 Press the “F4” button to

save the Output List
assigned to this service

Note: The input will be
saved and the display will be
ready to start new input.

10 Repeat steps 4 – 9 until all

Services, which need
outputs assigned in the
Output Lists have been
programmed.

11 Press the “MENU” button

on the display pad to return
to the previous menu.

Service _ _
Outputs , , , , , , ,
, , , , , , ;

[1] Service [4] Wash Settings
[2] Outputs [5] Set Date Time
[3] Output Lists [6] Set Password

Wash Configuration 58

Overview

Introduction

In this chapter

TUNNEL MASTER JR MANUAL

Chapter 3

Operating Procedures

The Operating Procedures chapter will provide the user with an
explanation of how to operate their Tunnel Controller, process
customer vehicles and review operations through 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 operator that they will obtain accurate reports
and prevent potential employee errors or possible theft.

This chapter covers the following topics:

Topic See Page

Wet Down Wash 56
Processing Vehicles 57
Viewing Service Counts 60
Shift Break 62
Printing Reports 63

Operating Procedures 59

Introduction

Menu
Options

TUNNEL MASTER JR MANUAL

Main Wash Menu

After setting up the various wash settings and services the user is now
ready to wash cars. The main wash menu is where many of the day to day
activities will be performed. It is important to train personnel in the proper
selection of these menu options to assure 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 their function.

Item Menu Option 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 allows the user to activate any

equipment outputs, which have been
designated to activate whenever the operator
chooses this wetdown option.

3 Configure Wash Allows user to configure wash settings ans

services, explained in-depth in Chapter 2.

4 View Counts This menu gives the ability to view counts,

number of times the various services have
been processed during the current shift

5 Print Reports From this menu option a user can print

various financial reports, if there is an
optional report printer attached to the
controller.

Operating Procedures 60

Introduction

Procedures

TUNNEL MASTER JR MANUAL

Wet Down Wash

The Wet Down process is the first thing the opening person should do to
prepare the wash for the first customer. When selected the process is setup
to activate all relays (outputs) which have been designated to turn on
during the Wet Down cycle. The cycle time is setup in the Wash Settings
menu. By “wetting down” the cloth equipment and perhaps charging the
foaming manifolds in the wash the wash will be better “tuned” to process
the first vehicle and therefore provide a more consistent wash to the
customer.

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
set it will be necessary to
enter the password before
the main menu can be
accessed.

2 Press the numeric key “2” to

select Wet Down Wash.

Note: The relays will be
activated and you will be
returned to the main display
screen. A second to second
countdown will start next to
the word “WETDOWN.”
This system will continue
counting down until it
reaches 0 and then shut all of
the activated relays off.

[1] Shift Break [4] View Counts
[2] Wet Down Wash [5] Print Reports
[3] Configure Wash

ICS OEM Tunnel Controller 10:25:35 PM
VER 1 REV 5.11 04/15/2002

WETDOWN 085 SECS CARS 0000

Operating Procedures 61

Introduction

Diagram

TUNNEL MASTER JR MANUAL

Processing Vehicles

After the Wet Down has been completed the operator is now ready to
process vehicles. As the vehicles are guided onto the conveyor the
attendant can “load” the vehicle into the Entrance Keypad at the front of
the wash. The process is simple and easy to follow.

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 the
particular function associated
with the button has been loaded

The Receipt button should be
pressed after all desired
services have been entered, but
before the Roller button is
pressed.

The AC button can be pressed
if an error has been made and
the user wishes to reprogram
the vehicle into the system.

Operating Procedures 62

TUNNEL MASTER JR MANUAL

Processing Vehicles (Non-Stacking)

Procedures

These are the procedures for a non-stacking system.

Step Non Stacking Action Keypad Response

1 Press the numeric button

associated with the service
the customer has purchased.

2 Press any additional extra

service buttons for other
services the customer may

The red indicator light will light up
indicating the input has been
accepted

The red indicator light will light up
for each additional service button
pressed indicating the input has been
accepted

have purchased.

3 Press the Receipt button to

Customer receipt will print out.

print a customer receipt, if
there is a receipt printer
attached to the Entrance
Keypad.

4 Once all desired services are

“loaded”, press the “Roller”
button to start the vehicle

The indicator light on the roller
button will light up indicating that
the input has been accepted.

through the wash.

Note: Once the roller button
has been pressed the roller
relay will be activated and a
roller will come up to
process the vehicle through
the wash

5 Vehicle will start through the

wash breaking the gate
switch.

All indicator lights will go out after
the car has reached minimum car
length.

Note: All the indicator lights
will stay lit until there has
been enough chain travel to
reach minimum car length
set in wash settings.

Operating Procedures 63

TUNNEL MASTER JR MANUAL

Processing Vehicles (Stacking)

Procedures

Status Step Stacking Action Keypad Response
Ready 1 Press the numeric button

2 Press any additional extra service

3 Press the Receipt button to add

4 Press the Roller Button to

5

6 If you hit the AC button.

Stack Pick 1 Press the AC button to view the

2 If you press a flashing number

3 If you press the Receipt button.

These are the procedures for a stacking system.

The red indicator light will light

associated with the service the
customer has purchased.

buttons for other services the
customer may have purchased.

the car to the stack.

process the next car on the stack.

Vehicle will start through the
wash breaking the gate switch.

cars on the stack.

key.

up indicating the input has been
accepted
The red indicator light will light
up for each additional service
button pressed indicating the
input has been accepted
The number that corresponds to
the stack will flash for 5 seconds.
Then the light will turn off. If no
base wash is selected, this key is
ignored. If you want to print a
receipt, hit the button a second
time.
The Roller light will turn on and
the roller will fire. If you have
auto roller set to Y, this is not
necessary.
Once the car reached minimum
car length, the car will come off
of the stack.

This will clear any services if
selected. If no services are
selected, the AC key will toggle
you in and out of the stack pick,
if cars are on the stack.
You will see the lights on the
numbers flashing if there are any
cars on the stack. This status
will only stay active for 5
seconds of inactivity before it will
return you to the Ready status.
This will take you to the stack
edit status and the services for
that car will display.
This will print the last car added
to the stack, if there are cars still
on the stack.

Operating Procedures 64

Introduction

Helpful Tip ☺

TUNNEL MASTER JR MANUAL

Viewing Service Counts

There will be times during the course of daily operations that management
personnel will want to review sales counts. This can be down quickly
from the View Counts menu option. This option allows the user to
quickly determine how many of each service option have been processed
during the current shift.

If the user did not purchase the optional report printer the Viewing Counts
menu option will be the only way they can track sales during a shift.
Once the shift is either manually closed or automatically bumped by the
system the counts will be cleared 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 shift is closed.

Procedures

Follow these procedures to view the service counts for the current shift.

Step Action Screen Displays

1 Access the Main Menu by

pressing the “Menu” button

[1] Shift Break [4] View Counts
[2] Wet Down Wash [5] Print Reports
[3] Configure Wash

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.

2 Press the numeric key “3” to

select View Counts.
Unloaded = Vehicles washed

00 – UNLOADED 0000 CARS WASHED: 135
VIOLATIONS: 0

Press [ENT] to Continue, [MENU] to Exit

without a service being
programmed.

Cars = # of cars washed
Violations = Number of

times maximum car length
exceeded.

Operating Procedures 65

Procedures

TUNNEL MASTER JR MANUAL

Viewing Service Counts

Continue following these procedures to view the service counts for the
current shift.

Step Action Screen Displays

3 Press the {ENT] button on

the display keypad to
advance to additional
services.

4 Repeat Step 3 to review up to

32 possible services.

Note: Any service number
skipped in the service setup
will display as [EMPTY]

5 Press the [MENU] button on

the display pad to return to
the Main Menu

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

[1] Shift Break [4] View Counts
[2] Wet Down Wash [5] Print Reports
[3] Configure Wash

Operating Procedures 66

Introduction

Helpful Tip ☺

Procedures

TUNNEL MASTER JR MANUAL

Shift Break

There are two ways to break (close) a shift. The first is to go into Wash
Settings and select Yes for the Auto Shift menu option. This option will
automatically close the shift at midnight each night. The second option is
to go to the main display menu and select Shift Break. This option allows
the user to close a shift manually at a time selected by the user. This
option would be used by operators that wish to balance their shifts at the
end of the day instead of waiting until the next morning.

It is very important that one of the two options be used each day. Failure
to close a shift will result in car and service counts being inaccurate, as
they would run multiple days into one 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!

Follow these procedures to manually break (close) the current shift.

Step Action Screen Displays

1 Access the Main Menu by

pressing the “Menu” 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.

2 Press the numeric key “1” to

select Shift Break.

Note: A shift report will print
automatically at this point if
there is an optional report
printer attached.

3 Using the numeric keypad

press either “Y” for yes, or
“N” for no to close the shift
at this time.

4 Press the [ENT] button on

the display pad to enter
selection and return to the
Main Menu

[1] Shift Break [4] View Counts
[2] Wet Down Wash [5] Print Reports
[3] Configure Wash

Shift Break

Bump Shift (Y/N)?

Shift Break

Bump Shift (Y/N)? N

[1] Shift Break [4] View Counts
[2] Wet Down Wash [5] Print Reports
[3] Configure Wash

Operating Procedures 67

Introduction

Menu
Options

TUNNEL MASTER JR MANUAL

Printing Reports

Anytime during the day or after shutdown it is possible to print out
reports. These reports include the following options:

1. Shift History

2. Monthly Summary

3. Yearly Summary

4. Wash Settings

The following is a list of menu options in the Reports menu and a brief
explanation 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 is lost or destroyed.

2 Monthly Summary Monthly summary report will give the user

a quick report showing all activity for the
current calendar month.

3 Yearly Summary Yearly summary report will give the user a

quick report showing all activity for the
current calendar year.

4 Wash Settings This will print the wash settings, outputs,

services and output lists.

Operating Procedures 68

Picture

g

TUNNEL MASTER JR MANUAL

Printing Reports

This is a picture of a shift report and an explanation of the entries. The
summary reports provide the same basic information.

Date / Time and station ID information. ID
information is setup in the Headers menu option
in Wash Settings.

Shift Start and Stop times captured from the
date time settings in the controller.

Service, Qty and Amount are the names of
services processed during the shift, the quantity
or number of the services processed and the
dollar value of the quantity of the service times
the selling price.

Non Tax Sales = total sales that were non
taxable
Sales @ Tax Rate 1 & 2 = Total sales of all
services 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 sold that were at the set tax

Car Count = Total services setup as base
washes that were processed.
Invalid Count = The number of times that
Minimum Car Length was not achieved
Violation Count = The number of times that the
gate switch was continuously activated that
exceeded Maximum Car Len

Override Activity displays the Outputs and
number of times the output was activated in the
following manners.

Auto = The number of time the system
automatically activated the output to process a
vehicle.

Manual = The number of time the relay toggle
switch was manually turned on to activate an
output.

Time = Is the total number of seconds the
manual switch was turned on while it was

th.

Operating Procedures 69

Procedures

TUNNEL MASTER JR MANUAL

Printing Reports

Follow these procedures to print a shift report.

Step Action Screen Displays

1 Access the Main Menu by

pressing the “Menu” 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.

2 Press the numeric key “5” to

select Print Reports.

[1] Shift Break [4] View Counts
[2] Wet Down Wash [5] Print Reports
[3] Configure Wash

[1] Shift History [4] Wash Settings
[2] Monthly Summary
[3] Yearly Summary

3 Press the numeric key “1” to

select Shift History.

4 Press the [F2] key on the

numeric keypad to advance
to the desired shift to print

>Shift 1006 – 04/15/2002 06:57:57pm<
Shift 1007 – 04/16/2002 06:45:25pm
Shift 1008 – 04/17/2002 06:35:52pm
F1=PREV F2=NEXT F3=PRINT

Shift 1125 – 10/25/2002 06:45:52pm
>Shift 1126 – 10/26/2002 06:57:33pm<
Shift 1127 – 10/27/2002 06:35:52pm
F1=PREV F2=NEXT F3=PRINT

and select by having the ><
next to the desired shift

5 Press the [F3] key to print

the highlighted shift.

6 Press the [MENU] button on

the display pad to return to
the Reports Menu

[1] Shift History
[2] Monthly Summary
[3] Yearly Summary
[4] Wash Settings

Operating Procedures 70

Procedures

TUNNEL MASTER JR MANUAL

Printing Reports

Follow these procedures to print either a Month or Yearly summary report.

Step Action Screen Displays

1 Access the Main Menu by

pressing the “Menu” 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.

2 Press the numeric key “5” to

select Print Reports.

[1] Shift Break [4] View Counts
[2] Wet Down Wash [5] Print Reports
[3] Configure Wash

[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 either Monthly

Summary or Yearly
Summary.

Note: The desired report will
print on the optional report
printer.

4 Using the numeric keypad to

select either “Y” for Yes, or
“N” for No to clear the
monthly numbers.

5 Press the [ENT] key to return

to the Reports menu.

Monthly Summary Report

Clear Monthly Summary (Y/N)?

Monthly Summary Report

Clear Monthly Summary (Y/N)? N

[1] Shift History [4] Wash Settings
[2] Monthly Summary
[3] Yearly Summary

Operating Procedures 71

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Chapter 4

Trouble Shooting

Tunnel Master Jr. Controller System Diagnosis

The following diagnostic procedures are provided for use only when the ICS Tunnel
Controller System has stopped responding or is not functioning. If you determine
after reviewing the diagnostic procedures the system is malfunctioning, write down
the specific conditions and contact your OEM vendor.

Entrance Keypad

Before examining the ICS Relay Controller, a test should be performed at the
Entrance Keypad to ensure that it is functioning properly. Press the AC (All Clear)
key located in the lower right corner of the numeric keyboard two or three times
while there are no cars in or near the gate switch. Now press any of the numbered
service buttons on the keypad. The indicator light should turn red as soon as the
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
Relay Controller

Check the Logic light in the upper right hand corner of the keypad. This light
should be blinking indicating 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 OEM Relay
Controller.

Wash Controller Response

At the Controller Relay Box verify that there is a read out on the display at the top
of the relay box. If not, the relay box may not have power.

Check the +5V DC light located in the upper left corner of the relay box display
panel. This light should be lit at all times to verify that the controller has power.

Check the Logic light in the upper left corner of the relay box display panel. This
light should be blinking indicating that the system processor is functioning.

Troubleshooting 72

TUNNEL MASTER JR MANUAL

Wash Controller Input Check

There are four possible inputs into the Controller that if not functioning could cause
the system to not respond properly. There are indicators in the upper left corner of
the relay box display panel. Check to see that the inputs and indicator lights are
functioning normally.

• Clock – With the conveyor running the clock light should be blinking
consistently. This insures that the pulse switch is operating properly. If this is
not operating properly, you can go into the wash settings and change Auto
Pulse to Y. With this option turned on, the controller will simulate a pulse count.
In order for this to work properly, you must have the Auto Pulse Period correct
in the wash settings. Please see page 36 for the Auto Pulse Period formula.

• Gate - With the conveyor running and a vehicle passing through the gate
switch (electric eye) the Gate indicator light should stay lit the entire time a
vehicle is activating the gate switch. If this function is not operating properly,
you can go in to the wash settings and change the Auto Gate to Y. With 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. In order for this function to work properly, you
must set the Auto Gate Delay in the Wash Settings. The Auto Gate Delay is the
distance from where the start of the car normally is and the Gate sensor.

• Tire – With the conveyor running and a vehicle passing through the tire switch
the Tire indicator light should stay lit the entire time a vehicle is activating the
tire switch.

• Panic – If a Panic circuit has been wired into the controller, anytime a stop
switch is activated the Panic indicator light will go out. Once the stop switch or
circuit is open again the light will come back on and the conveyor will become
operable again.
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 sure there is enough oil.

If any of the above inputs are not functioning properly first check the device. If the
device is working properly then check the wiring to the circuit board in the relay box
for loose or disconnected wires to the termination points in the upper left corner of
the Relay Box.

Troubleshooting 73

TUNNEL MASTER JR MANUAL

Entrance Keypad Diagnostics

To test the keypad, there is a diagnostic mode you can put it in to verify its
functionality. Remove the 4 screws and remove the top of the keypad. Flip it over,
you will see the dip switch settings. Turn dip switch 4 on and press the reset
button to the immediate left of the dipswitches. Now, 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
roller button will be off, if you hit it once, it will turn on, if you hit it again, it will turn
off. If you hit the AC button, it will toggle all of the number keys. If you hit the $
sign or the up arrow, the printer will print, “this is a test…”, every time you hit either
button. If any of these keys do not respond correctly, contact your distributor for a
replacement keypad.

Troubleshooting 74

TUNNEL MASTER JR MANUAL

y

ICS System Trouble Shooting

Tunnel Master Junior Relay Box

Symptom Cause Remed

Manual Override not
working

Relay not firing

Jumper JP 11 is off Put Jumper on JP 11
Ribbon cable(s) not plugged in Re-attach Ribbon cable
Ribbon cable(s) plugged in

incorrectly
Panic Condition is present Disable the panic
Equipment Problem Contact your equipment vendor
Fuse Blown Test fuse at bottom of board

Output not selected for Service
PLU# in Outputs List.

Ribbon cable(s) plugged in
incorrectly
Check position of relay toggle
switch
No power to Relay Box Check 110VAC power to relay box
Pulse / Gate not operating
correctly

Re-attach Ribbon cable

where spares are located
Add relay to outputs list for
selected service PLU#.
Re-attach Ribbon cable

Move switch to down position

Please check the Wash Controller
Input Check on page 67.

No relays firing

Ribbon cable(s) loose Re-attach Ribbon cable
Panic condition present Disable panic
Pulse / Gate not operating

correctly

Please check the Wash Controller
Input Check on page 67

My display is too dark. Contrast is not set correctly. Please see page 14 for a diagram

of where the contrast dial is and
adjust as needed.

None of my selective
outputs are firing.

Unloaded car If a roller is fired with no services

selected, the controller will only
fire Mandatory outputs. This is
known as an unloaded car.

Troubleshooting 75

TUNNEL MASTER JR MANUAL

Entrance Keypad

Symptom Cause Remedy

Key pad not responding

LED’s are coming on
randomly.
Keypad failure Put keypad in diagnostic mode

Keypad diagnostic fails Keypad failure Contact your distributor for a

Keypad address not correct. In most circumstances, the keypad

address in the wash settings
should be 5. See page 24 for
keypad addressing.

Loss of power to Entrance Keypad Check Power LED, if voltage

present LED will flash
OEM Relay Box has no power Reconnect 110VAC to relay box
Wires and/or plugs loose. Re-connect as necessary

Keypad and Relay box jumpers
are incorrect.
Keypad and Relay box jumpers
are incorrect

Check the proper jumper settings

on pages 16 and 23.

Check the proper jumper settings

on pages 16 and 23.

and press each button to insure

proper functionality. See Entrance

Keypad diagnostics on page 67.

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 the pulse switch. Please refer to Wash Controller

Input Check on page 67.

My receipts are not printing.

My reports are not printing.

Printer is turned off. Be sure that your printer is turned

on and that the error light is not
on.

ReceiptAddress is incorrect. Go in to wash settings and verify

that the receipt address is
correct. If the receipt printer is
hooked up to the keypad, it
should be address 5. If the
receipt printer is hooked up to the
relay box, then the address
should be 0.

Printer is turned off. Be sure that your printer is turned

on and that the error light is not
on.

ReportAddress is incorrect. Go in to wash settings and verify

that the report address is correct.
If the report printer is hooked 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.

Troubleshooting 76

TUNNEL MASTER JR MANUAL

My Epson Dot Matrix printer
is printing garbage

All of my equipment is
shutting off half way through
the tunnel.

I am getting unloaded cars
on my shift reports.

Printer dipswitch settings are
incorrect.

Faulty Gate Switch. Invalid /
Max car violation.

Min Car Length set too high. If your Min Car Length is set too

Cars not being loaded properly. Roller is called up manually

Turn printer upside down.
Loosen the screw to get to the
dipswitches. DSW1 # 3 should
be on and everything else should
be off.
Test your Gate switch. If you
have photo eyes, put something
in front of them and see if the
gate light on the relay box to see
if it comes on. If you have a logo
loop, put something metal over
the 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.
high, and a car that is less than

the min car length comes through
the eye, the system will not
register it as a car and the
equipment will shut off.

without a service being loaded.

Antibounce is set incorrectly. Your antibounce should be

higher than your pulse length and
less then your min car length.

Troubleshooting 77

TUNNEL MASTER JR MANUAL

Appendix A

Appendix 78

TUNNEL MASTER JR MANUAL

Appendix 79

TUNNEL MASTER JR MANUAL

Appendix 80

Index

A

TUNNEL MASTER JR MANUAL

display light · 31

Extend

output menu item · 43

AntiBounce · 36
Assigning Outputs · 51
AutoGate · 37
AutoGateDelay · 37
AutoPulse · 37
AutoPulsePeriod · 37
AutoShift · 38
AutoStopPeriod · 37

C

CarCount · 39
Configure Wash

overview · 29
menu options /function · 33

D

Date

setting date · 34

Date Time

Configure Wash Menu · 33

Dip Switch

relay box · 17
relay box, location · 15

Dip Switch Settings

entrance keypad · 25

Dip Switches

entrance keypad functions · 25

DisplayCars · 39

F

Flash

output menu item · 43
FlashOff · 38
FlashOn · 38
Footer1 · 39

H

Header1 · 38

I

Installation

relay box · 7-8
Invalid Count

report entry · 64
InvertGate · 37

J

Jumper Functions

entrance keypad · 24
Jumper Settings

relay box · 15

E

Electric Eye

wiring · 10

Entrance Keypad

button 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 Keypad

picture · 30

relay box · 30
Entry keypad,
relay box, button functions - 31

Index 81

K

KeyDelay · 38
KeypadAddress · 39

L

Look

output menu item · 43

M

Main Wash Menu

menu item / function · 55

Manual Override

jumper setting · 16

MaxCarLength · 36

MinCarLength · 36
Monthly Summary

menu item / function · 63
Mounting

entrance keypad · 20

printer · 27

relay box · 7

N

Name

output menu item · 42

service menu item · 49-50
NetErrorCount · 40

O

Operating Procedures · 54
Output

output menu item · 42-46
Output Lists

menu item / function · 51-53
Outputs

Configure Wash Menu · 33

menu items · 41

procedures for programming · 46, 47
Outputs List

Configure Wash Menu · 33
Outputs Worksheet · 44, 45
Override Activity

report entry · 64

P

Panic

output menu item · 44
Panic Circuit

wiring · 12-13
PanicStop · 37
Part

output menu item · 43
Password

accessing with password · 32

entering · 32
Price

service menu item · 47
Printer Installation

mounting and wiring · 27
Printing Reports

example report · 64

menu options / function · 63

Month 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 menu item · 48
Receipt / Report Printer

features · 26

specifications · 26
ReceiptAddress · 40
Relay Box · 5

circuit board reset button · 15

description · 5-6

dip switch functions · 15

dip switch settings · 15

entry keypad · 30

fuse tester, location · 6

installation · 7-8

interior picture · 6

picture · 6

toggle switches · 5

wiring · 7-8
RelayAddress2 · 39
Report/Receipt Printer

picture · 26
ReportAddress · 40
Reset Button

relay box circuit board · 15
Roller Button

entrance keypad · 18
RollerControl · 37

S

Service

output lists menu item · 52

service menu item · 47
Services

Configure Wash Menu · 33

menu items / function · 47

procedures for programming · 49-50
Shift · 38
Shift Break

procedures · 62

menu item / function · 55
Shift History

menu item / function · 63
Start

output menu item · 42

Index 82

TUNNEL MASTER JR MANUAL

T

TaxRate1 · 38
TaxRate2 · 38
Time

setting time · 34

Tire Switch

wiring · 11

Trouble Shooting · 67

Entrance Keypad ·67-69
Relay box · 67-69
symptoms · 70-72

Type

output menu item · 42
service menu item · 47

V

View Counts

menu 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 & functions · 36-40

procedures for programming · 41
Wet

output menu item · 42
Wet Down Wash

menu item function · 55

operating procedure · 56
WetDownPeriod · 37
Wiring

entrance keypad · 21

printer · 27-28

relay box · 7-8

Y

Yearly Summary

menu item / function · 63

Index 83