Tunnel Master® wbc
Installation Guide - Version 10
Information in this manual is subject to change without notice. The example
companies, organizations, products, domain names, email addresses logos,
people, places and events depicted herein are fictitious. No association with any
real company, organization, product, domain name, email address, logo, person,
place or event is intended or should be inferred unless otherwise noted. No part
of this manual may be reproduced or transmitted in any form or by any means,
electronic or mechanical, for any purpose without the express written permission
of Innovative Control Systems, Inc.
Innovative Control Systems and its product trademarks in this manual are
trademarks of Innovative Control Systems, Inc. All other marks are property of
their respective owners.
© 2018 Innovative Control Systems, Inc.
Innovative Control Systems, Inc.
1349 Jacobsburg Road
Wind Gap, PA 18091
(610) 881-8100
Contents
Chapter 1: Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Version Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hardware Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Planning for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Chapter 2: Site Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Determine the Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Equipment Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Mounting the Tunnel Master® wbc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Power Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Conduit Run Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Site Grounding Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Recommended and Accepted Grounding Methods. . . . . . . . . . . . . . . . . 15
Wire Gauge and Conduit Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Chapter 3: Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Locating Boards and Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Tunnel Master® wbc AC Power Terminations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Main CPU Board Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
WBC Main CPU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Main CPU Board Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Delayed Panic Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Input Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Input Board Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Manual Bypass Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Transformer Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Transformer Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Relay Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Relay Board Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Jumpers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Start/Stop Inputs Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Manual Bypass, Conveyor, and Horn Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Conveyor Relay Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Conveyor Relay DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Pulse Switch Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Tunnel Master® wbc - Installation Guide 3 Contents
Main Inputs Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Common Relay Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Common Relay Output Wiring (cont.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Jumper Test Point Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Main CPU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Third Party Kiosk to Tunnel Master® wbc Terminations . . . . . . . . . . . . . . . . . . . . . . . . .45
Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Ultrasonic Truck Bed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Ultrasonic Truck Bed Sensor Mounting Recommendations. . . . . . . . . . 49
Ultrasonic Sensor Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Ultrasonic Sensor Power Supply Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Ultrasonic Truck Bed Sensor Wiring Components . . . . . . . . . . . . . . . . . . . 51
WBC AC Power Terminations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Ultrasonic Sensor Power Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Connections from WBC to the Ultrasonic Converter Box (Power) . . . . 52
Ultrasonic Sensor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Ultrasonic Sensor Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Powering the Ultrasonic Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Chapter 4: Communications Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Installation Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
RS-232 COMM Terminal Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
RS-485 Wiring Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Chapter 5: Install Entrance Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Entrance Keypad Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Second Entrance Keypad Mounting and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Second Entrance Keypad Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Second Entrance Keypad Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Second Entrance Keypad Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Entrance Keypad DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Chapter 6: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Preventative Maintenance and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Central Log Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Serial Debug Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Tunnel Master® wbc - Installation Guide 4 Contents
List of Figures
Figure 1. WBC Mounting Box Footprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 2. Universal Ground Symbol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 3. WBC Internal Components Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 4. AC Power Terminations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 5. Main CPU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 6. Input Board Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 7. Delayed Panic Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 8. Input Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 9. Normal and Bypass Operation Settings on the Input Board. . . . . . . . . . . . . . . . . . . . . . . 27
Figure 10. Transformer Selector on the Input Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 11. Relay Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 12. Jumpers for Relay Board Terminal Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 13. Wiring for Start/Stop Stations and Emergency Stop Stations . . . . . . . . . . . . . . . . . . . . 31
Figure 14. Wiring of On-Board Relays for Conveyor Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 15. Conveyor Relay Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 16. Pulse Switch Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 17. Main Inputs Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 18. WBC Relay Board Terminations Common Relay Output Wiring . . . . . . . . . . . . . . . . . . 37
Figure 19. Common Relay Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 20. Jumper Test Point Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 21. Main Figure 21: CPU Board DIP Switches and Reset button Location . . . . . . . . . . . . 43
Figure 22. Non-ICS Kiosk (not an Auto Sentry) to Tunnel Master® wbc Terminations . . . . . . . . 46
Figure 23. Exterior Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 24. Ultrasonic Sensor Mounted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 25. Ultrasonic Sensor Dimensions (dimensions are in mm) . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 26. Two RS-485 Comm Tiers on Main CPU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 27. WBC Power Terminations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 28. WARNING Label located below Tunnel Master® wbc Power Terminations. . . . . . . . 51
Figure 29. Ultrasonic Sensor Power Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Figure 30. Ultrasonic Sensor Comm Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 31. Power the Sensor (Black, Brown, and Blue wires). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Tunnel Master® wbc - Installation Guide 5 List of Figures
Figure 32. Pickup Bed Sensor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Figure 33. RS-232 COMM Terminal Wiring Diagram (Main CPU Board) . . . . . . . . . . . . . . . . . . . . . 57
Figure 34. RS-485 Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 35. Keypad Connectors (Keypad Board). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 36. Tunnel Master® wbc Power Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 37. AC Power Terminations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Figure 38. Main CPU Board RS-485 Comm Terminal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 39. Keypad Circuit Board Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 40. Keypad Reset and DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Tunnel Master® wbc - Installation Guide 6 List of Figures
List of Tables
Table 1. Dimensions, Measurements, and Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Table 2. Max. Number of Wires (THHN) in a Given Conduit Size. . . . . . . . . . . . . . . . . . . . . 16
Table 3. WBC Internal Component Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Table 4. Main CPU Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Table 5. Input Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Table 6. Input Board Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Table 7. Relay Board Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Table 8. Jumper Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Table 9. Main CPU Board DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Table 10. Input Board DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Table 11. Exterior Description for the. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Table 12. Ultrasonic Truck Bed Sensor Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Table 13. Ultrasonic Sensor Communications Wiring Connections. . . . . . . . . . . . . . . . . . 53
Table 14. Key to Sensor Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Table 15. Keypad Connector Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Table 16. 12VAC Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Table 17. Comm Cable Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Table 18. Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Table 19. DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Tunnel Master® wbc - Installation Guide 7 List of Tables
Tunnel Master® wbc - Installation Guide 8 List of Tables
CHAPTER 1: Installation Overview
This document was written for the installation of the Tunnel Master® wbc to assist technicians and
electricians. A thorough understanding of electrical wiring, installation, codes, and safety
protocols is required. Additionally, some familiarity with car wash tunnel equipment and
installation is recommended. No prior experience with the Tunnel Master® wbc (Web Based
Controller) is required. The Tunnel Master® wbc is also known as the WBC. This guide should be
supplied to the electrician prior to the installation of conduit and wiring to ensure the WBC system
is installed properly. Faulty installations are the major cause of system malfunctions. The Tunnel
Master® wbc system must be installed exactly as described in this manual to ensure its reliability
and proper operation.
WARNING: Failure to properly install the WBC system will void the warranty.
Innovative Control Systems provides technical support for customers and installers:
1-800-246-3469
Many of the WBC system features were integrated at the request of current car wash operators.
We welcome your feedback and want to assure you that ICS will always remain the industry leader
in car wash controller and management systems.
By reading the information and performing the procedures in this manual, you should be able to
perform the following:
Install the WBC system-level wiring
Install the WBC communications wiring
Troubleshoot problems if they occur
Related Documents
Tunnel Master® wbc User Manual
Version Considerations
This document is Version 10.0 released June 28, 2018. Version 10.0 of this document includes
content based on the following ICS software versions:
Controller software version 1.2 B51
Controller software version 1.3B10 (only available if hardware is compatible)
Tunnel Master® wbc - Installation Guide 9 Installation Overview
Hardware Specs
Unit weighs 130 lbs
Hinged panel design measures 32'' W × 40'' H × 12'' D
IP-based tunnel controller capable of handling:
▪ 192 outputs
▪ 48 inputs
Graphics display shows the status of all inputs and other tunnel status indicators
Web interface for easy configuration
Firmware update over network
Main CPU board
Up to four directly connected relay boards
Input board
All boards powered by 24 V DC from power supply:
▪ Isolated 12 V DC for display back light
▪ 12 V AC RS-485 isolation and 16 main inputs
All isolated inputs powered from separate external AC supply
Dedicated universal power supplies (UPS) 1500VA/865 Watts output capacity
Planning for Installation
Before you begin, please read this entire manual.
Permanent connections must be installed by a licensed electrician and must comply in
accordance with all local and national codes.
Wiring can be contained in rigid PVC conduit or metal conduit.
High-voltage (AC) and low-voltage (DC) must not be combined in a common conduit, junction
box, or wire trough.
Power for the Tunnel Master® wbc and any peripherals must come from the dedicated UPS, as
supplied by ICS.
The Tunnel Master® wbc and peripheral equipment must be properly grounded.
Test connections in the manual override position prior to system start-up.
Before disposing boxes and cartons, look through to make certain all manuals, cables,
connectors, and more have been removed.
Tunnel Master® wbc - Installation Guide 10 Installation Overview
CHAPTER 2: Site Planning
Careful planning for the layout of the site will help eliminate possible problems with the start-up
of your system and will ensure continued, reliable system operation. In the site planning stage,
keep the following objectives in mind:
Determine the site layout.
Prepare to have all the necessary tools and parts.
All permanent wiring connections must be installed by a licensed electrician that must comply
with local and national codes.
Determine the Location
The following are a few primary concerns to consider when determining the site layout:
The Tunnel Master® wbc must be securely mounted on a dry, non-corrosive interior wall or
surface in the equipment room of the car wash.
The unit has been designed to operate in an environment of 32° F to 122° F (0°C to 50°C).
The unit is 130 lbs., 32'' W × 40'' H × 12'' D with a hinged-panel door. Hinges are on the right.
The door swings open from left to right.
A minimum of 48 inches of clearance is recommended. This clearance should be available both
in front of the door and on the wall to the right of the unit. This minimum will give enough
clearance for the door to swing out and be fully opened without interfering with entrances
and exits from the equipment room.
The WBC box must be located so that conduit connections can be easily made and the relays
can be readily accessed.
Recommended minimum mounting height of 32'' off ground to the bottom of the WBC box.
Installer shall first follow any local codes which supersede this recommendation.
Tunnel Master® wbc - Installation Guide 11 Site Planning
Equipment Dimensions
When mounting the unit, minimum clearances must meet local codes.
Dimension Amount Notes
Width. 32'' —
Height. 40'' —
Depth. 12'' Includes the plastic face.
Weight. 130 lbs. Inclusive of the box, board, and door.
Operating Temp.
Range.
Frequency. 60 Hz. —
Supply Voltage. 110-120 VAC —
Max. Amps. 6.0 Amps. —
Power Supply. 15 Amps. Power must come from a dedicated, 15-Amp. breaker.
IPX0 Rating. Ordinary rating. The Tunnel Master® wbc is not rated for protection against dust
Table 1: Dimensions, Measurements, and Ratings
32° F to 122° F
0° C to 50° C
Interior, non-corrosive surface.
and liquid ingress.
Tunnel Master® wbc - Installation Guide 12 Site Planning
Mounting the Tunnel Master®
wbc
Figure 1. WBC Mounting Box Footprint
Tunnel Master® wbc - Installation Guide 13 Site Planning
Power Requirements
Electrician must provide a dedicated 15 Amp, 120 V AC circuit to power the Tunnel Master®
wbc box. This dedicated circuit must supply the UPS. The UPS will supply power to the WBC.
A separation of 120 V AC and 24 V AC shall be maintained for all field-wiring circuits. All 24 V AC
circuits must be supplied by a class-2 transformer, which is to be provided by the electrician.
Electrician must determine proper size of transformer, depending on total required power
consumption.
The Tunnel Master® wbc unit must be properly grounded.
See “Site Grounding Considerations” on page 15.
Conduit Run Guidelines
When running wires to and from the Tunnel Master® wbc unit, follow these guidelines:
Punch conduit holes through bottom of WBC box whenever possible.
Use wiring channels inside WBC box (left and right sides) to contain wires.
Run a 14/3 cable, from a UPS output, to the 120 V AC terminal block. The terminal block is
labeled with L and N for Line and Neutral. There is a mechanical ground lug located in the
lower-right corner near the AC terminal block within the box. It is labeled with the universal
ground symbol.
All conduit runs should meet local and national codes. Conduit 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-torquing may cause enclosure breakage.
Tighten all wires on the circuit board terminal blocks to 15 inch-pounds. Over-torquing may
cause breakage.
All conduit must be rigid PVC or metal.
High-voltage (AC) and low-voltage (DC) must not be combined in a common conduit, junction
box, or wire trough.
Tunnel Master® wbc - Installation Guide 14 Site Planning
Site Grounding Considerations
The Tunnel Master® wbc and peripheral equipment must be properly grounded.
Recommended and Accepted Grounding Methods
Proper system grounding is an extremely important part of the system installation. Grounds for all
system devices should be wired to the breaker panel ground bus bar which, in turn, should be
grounded to a ground rod. A conduit ground does not provide a sufficient ground. It is
recommended that the neutral and ground bus bars be bonded together when it is not
prohibited by local codes.
Figure 2. Universal Ground Symbol
The universal ground symbol identifies the grounding lug connector located inside the lowerright hand corner of the Tunnel Master® wbc box.
WARNING: Improper grounding will void equipment warranty. Ground wire must be
connected to the ground lug. Failure to properly ground the unit could
result in unit failure and/or bodily injury.
Tunnel Master® wbc - Installation Guide 15 Site Planning
Wire Gauge and Conduit Size
When planning the orientation of the wiring runs, follow the applicable ICS wiring diagrams and
consider the layout of the components at the site.
To determine conduit size needed, see the table below for more information.
½ ¾ 1 1 ¼ 1½ 2 2 ½ 3
AWG 14
AWG 12
AWG 10
AWG 8
AWG 6
AWG 4
AWG 3
AWG 2
AWG 1
Table 2: Max. Number of Wires (THHN) in a Given Conduit Size
13 24 39 69 94 154 — —
10 18 29 51 70 114 164 —
6 11 18 32 44 73 104 160
3 5 9 16 22 36 51 79
1 2 6 11 15 26 37 57
1 1 4 7 9 16 22 35
1 1 3 6 8 13 19 29
1 1 3 5 7 11 16 25
1 1 1 3 5 8 12 18
Tunnel Master® wbc - Installation Guide 16 Site Planning
CHAPTER 3: Electrical Installation
The Tunnel Master® wbc is the control center for “firing” the various outputs or services in the
wash tunnel; for example, soap foamer, reclaim motor, and more. The Tunnel Master® wbc
provides for automatic, computer controlled or manual firing of the outputs. The system can
control up to 192 outputs and 64 inputs (48 of which are user-programmable).
Locating Boards and Terminal Blocks
This section provides details on boards, component locations, and terminal block identification:
Main CPU board
Input board
Up to four directly connected Relay boards
24 V DC power supply
12 V AC transformer used for supplying the following:
▪ Isolated 5 V DC RS485
▪ 5 V DC for 16 main CPU board inputs
▪ 48 auxiliary inputs on the input board
▪ All start/stop inputs
ID Description
1 Relay Board 1 Relays 1-24
2 Relay Board 2 Relays 25-48
3 Relay Board 3 Relays 49-72
4 Relay Board 4 Relays 73-96
5 Input Board
6 Main CPU Board
7 20V DC Power Supply
8 12V AC for all Isolated inputs
Power Terminations and Transformer
Table 3: WBC Internal Component Descriptions
Figure 3. WBC Internal Components Configuration
Tunnel Master® wbc - Installation Guide 17 Electrical Installation
Tunnel Master®
WBC AC POWER TERMINATIONS
6.0
A
120 VAC LINE FUSED
TERMINAL
120 VAC NEUTRAL
TERMINALS
GROUND
GROUND
LUG
NEUTRAL
LINE
(MUS T BE TER MINATED AT FUSED TERMINAL )
120 VAC FROM POWER
DI ST RI BUTI ON BOX 14/ 3
SHI ELDED WIRE E
A
C
L
A
C
N
G
N
D
POWER
BLACK
BLACK
WHITE
WHITE
GREEN
GREEN
SHIELD D RAIN NOT
TE RM INATE D
Controller
Keypad
ICS ONLY SIDE OF
TERM INAL BLOCKS
ELE CTRICIA N
SUPPLIED 18/4
SHI ELDED
+24v -24v
BROWN
BLUE
Ultrasonic Truck
Bed Sensor Box
ELE CTRICIA N
SUPPLIED 24/4
SHI ELDED
A
C
L
A
C
N
G
N
D
wbc
AC Power Terminations
Figure 4. AC Power Terminations
Tunnel Master® wbc - Installation Guide 18 Electrical Installation
Main CPU Board Overview
The main CPU board includes a microprocessor module and 16 main inputs. It drives up to four
in-box relay boards and one in-box input board.
A data flash module is included for storage of configuration settings. One eight-port DIP
switch is included.
One RS232 port is available for debug. The main CPU board drives the included PS2 keyboard
and 640 × 480 color display monitor.
One RS485 port with two connectors is included. It is available for connecting a wash selection
keypad.
LEDs are available for all the I/Os including the RS-232/485 connections.
LED indicators display the status of inputs. The main status LEDs include the following:
▪ LED1–Logic
▪ LED2–Auto pulse
▪ LED3–6 Reserved
▪ LED7–Chain travel
▪ LED8–Conveyor Status
Tunnel Master® wbc - Installation Guide 19 Electrical Installation
WBC Main CPU Board
Figure 5. Main CPU Board
Tunnel Master® wbc - Installation Guide 20 Electrical Installation
Main CPU Board Descriptions
The following table lists inputs available on the main CPU board. All inputs require 24 V max. line,
neutral, and ground.The following table describes Figure5, “Main CPU Board,”.
ID Description ID Description
1 RJ-45 Terminal for Network Connection 15 Display Connection Point
2 Flash Module* 16 Keyboard Connect Point
3 Eight-Port DIP Switch 17 Pulse Switch Connections
4 Status LEDs 18 Assigned Function Inputs
5 Input Board RJ-45 Terminal Connector 19 Expansion Inputs
6 Relay Board RJ-45 Terminal Connector
Relays 1-24
7 Status LEDs 21 Fuse 500mA
8 Relay Board RJ-45 Terminal Connector
Relays 25-48
9 Status LEDs 23 12V AC Input from Transformer
10 Relay Board RJ-45 Terminal Connector
Relays 49-72
11 Fuse 500mA
12 Relay Board RJ-45 Terminal Connector
Relays 73-96
13 Fuse 500mA
14 Input Power from 24V DC Power Supply
Table 4: Main CPU Board
*Removing the Flash Module for any reason will Void the Warranty.
20 RS-232 Comm Terminal
22 RS-485 Comm Terminal
Tunnel Master® wbc - Installation Guide 21 Electrical Installation
Main CPU Board Wiring Guidelines
Figure 6. Input Board Inputs
ID Terminal Block Input Name Description
1 Pulse Switch
Input
Table 5: Input Descriptions
PULSE SINK When using a normally open, two-wire pulse switch, use ter-
PROX GND
PROX POWER
SINK
GND
POWER
PULSE SRCE
GND
minals marked PULSE SINK and PROX GND.
See “Pulse Switch Wiring” on page 35.
When using a normally open three-wire pulse switch, use
terminals marked PROX POWER, PULSE SINK, and PROX
GND. System provides 18 V DC power.
See “Pulse Switch Wiring” on page 35.
When using a normally closed three-wire pulse switch, use
terminals marked PROX POWER, PULSE SRCE, and
PROX GND.
See “Pulse Switch Wiring” on page 35.
Tunnel Master® wbc - Installation Guide 22 Electrical Installation
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