Tunnel Control Station Installation Troubleshooting Guide€¦ · 04/01/2017 · TunnelWatch TCS Installation Troubleshooting Guide 6 07/13/17 Read ME! Before using this Guide Overview:

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Tunnel Control Station

Installation Troubleshooting

Guide

Copyright © 2013 by DRB Systems Inc. All rights reserved. All DRB Systems product names are trademarks or

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trademarks of their respective holders.

For TunnelWatch versions 2.12 and higher Manual revision 081513

TunnelWatch TCS Installation Troubleshooting Guide

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Table of Contents READ ME! BEFORE USING THIS GUIDE ............................................................................................................................ 6

OVERVIEW: ................................................................................................................................................................................ 6

HOW TO BE SUCCESSFUL USING THIS GUIDE:............................................................................................................................. 6

TUNNEL DEVICE ISSUES ........................................................................................................................................................ 7

WHAT TO DO WHEN A DEVICE DOES NOT TURN ON (EXCLUDING THE CONVEYOR, HORN OR ROLLER UP) ............................ 7

Overview ............................................................................................................................................................................... 7

Step-by-Step .......................................................................................................................................................................... 7 1st) Force the device on. ....................................................................................................................................................................... 7

2nd) Force the device on from the TunnelWatch computer to verify it is programmed properly. ........................................................ 7

3rd) Check that the device is programmed properly in TunnelWatch. ................................................................................................. 8

4th) Check the Service Selections configuration. ............................................................................................................................... 11

5th) Did the change help? ................................................................................................................................................................... 16

WHAT TO DO WHEN DEVICES DO NOT TURN ON AT THE CORRECT TIME ................................................................................ 16

Overview ............................................................................................................................................................................. 16

Step-by-Step ........................................................................................................................................................................ 16 1st) Check the Enter Switch. .............................................................................................................................................................. 17

2nd) Check the Pulse Switch. ............................................................................................................................................................. 17

3rd) See how the TunnelWatch software tracks a vehicle .................................................................................................................. 18

4th) Check that the Simulated Pulse and Simulated Enter switch are active. ..................................................................................... 20

5th) Check the Pulse Distance. ........................................................................................................................................................... 23

COMMUNICATIONS ISSUES ................................................................................................................................................ 27

WHAT TO DO WHEN A “STATIONS NO RESPONSE” OR “RRS COMM INTERMITTENT” MESSAGE APPEARS .............................. 27

Overview ............................................................................................................................................................................. 27

Step-by-Step ........................................................................................................................................................................ 27 1st) Verify TunnelWatch is running version 2.12 or higher. .............................................................................................................. 27

2nd) Verify Program Supervisor version 5.80 or higher. .....................................................................Error! Bookmark not defined.

3rd) Check the TunnelWatch System Status Screen. .......................................................................................................................... 28

4th) Check for the proper Relay Station(s) Port Assignment .............................................................................................................. 28

5th) Check the TCS and Record the Station Configuration settings. .................................................................................................. 30

6th) Reconfigure the system using the Config.bat configuration program. ........................................................................................ 32

7th) Check the BIOS Settings for the type of PC used at the site. ...................................................................................................... 32

8th) Check the RS- 422/485 I/O card, cables and connectors. ............................................................................................................ 32

9th) Swap the DB9 to RJ connector and Jumper Cable. ..................................................................................................................... 35

10th) Remove the TunnelWatch communications computer from the PC and check for proper configuration. ................................. 36

11th) Check the Logic Card settings................................................................................................................................................... 37

KEYPAD ISSUES ...................................................................................................................................................................... 40

KEY(S) ON THE KEYPAD ARE NOT FUNCTIONING PROPERLY .................................................................................................... 40

Overview: ........................................................................................................................................................................... 40

Step-By-Step........................................................................................................................................................................ 40 1st) Ensure the expected key assignments have been assigned to the correct keys............................................................................. 40

3rd) Contact DRB Systems Support ................................................................................................................................................... 46

TUNNEL ENTRANCE KEYPAD DOESN’T WORK ......................................................................................................................... 47

Overview ............................................................................................................................................................................. 47

Step-By-Step........................................................................................................................................................................ 47 1st) Connect the Keypad Terminal directly to the back of the TunnelWatch Computer. ................................................................... 47

2nd) Check the TunnelWatch software to verify that the configuration for the terminal is correct. ................................................... 47

3rd) Connect a spare keypad cable to the tunnel entrance terminal. ................................................................................................... 50

4th) Move the Keypad Connector to Serial Port B. ............................................................................................................................ 51

5th) Check the 12-volt power supply that powers the Keypad. .......................................................................................................... 53

6th) If none of the above troubleshooting steps resolve the issue. ...................................................................................................... 53


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CONVEYOR ENABLE CIRCUIT ........................................................................................................................................... 53

PROBLEMS WITH THE CONVEYOR ENABLE CIRCUIT DURING TCS INSTALLATION ................................................................... 53

Overview ............................................................................................................................................................................. 53

Conveyor Enable Test Troubleshooting Issues:.................................................................................................................. 54 1st) Turn the Conveyor Relay (1A) in the TCS box to the OFF position. .......................................................................................... 54

2nd) If the Green 24v LED is OFF. .................................................................................................................................................... 54

3rd) If the Green STOP LED is OFF. ................................................................................................................................................. 54

4th) Press and release a Start button. .................................................................................................................................................. 54

5th) Press and hold a Stop button. ...................................................................................................................................................... 55

6th) Release the Stop button. .............................................................................................................................................................. 55

8th) Press and release a Stop button ................................................................................................................................................... 56

12th) The Conveyor Enable Circuit does not respond as indicated .................................................................................................... 57

IRREGULAR START/STOP BUTTON WIRING ISSUES .................................................................................................. 57

3 OR 4 WIRE DAISY CHAIN STOP/START BUTTON ISSUES ........................................................................................................ 57

Overview: ........................................................................................................................................................................... 57

Step-By-Step........................................................................................................................................................................ 57 1st) Disconnect all 3 wires.................................................................................................................................................................. 57

2nd) Find the two wires that have continuity. ..................................................................................................................................... 57

3rd) Push in a stop and then a start button. ......................................................................................................................................... 57

4th) Measure continuity between the Start terminal (1A or any Start A terminal) and one of the two remaining wires. ................... 57

5th) Measure continuity between the Start terminal (1A or any Start A terminal) and the other wire. ............................................... 57

6th) You should get continuity on only one of the two wires. ............................................................................................................ 57

7th) Connect the wire that has continuity to STOP terminal 5B. ........................................................................................................ 57

8th) Connect the wire that does not have continuity to the STOP terminal labeled I-LOCK. ............................................................ 58

9th) If this does not correct the problem OR two pairs of wires have continuity during any of the above steps. ............................... 58

CONVEYOR ISSUES ................................................................................................................................................................ 58

CONVEYOR WON'T START........................................................................................................................................................ 58

Overview ............................................................................................................................................................................. 58

Step-By-Step........................................................................................................................................................................ 58 1st) Try the Stop/Start buttons ............................................................................................................................................................ 58

3rd) Check the Conveyor Enable Input LED ...................................................................................................................................... 58

4th) Check the Conveyor Relay LED. ................................................................................................................................................ 58

5th) Check the conveyor electrical connections to the TCS Unit ....................................................................................................... 59

6th) Check the configuration for the Auto On feature of TunnelWatch ............................................................................................. 59

2nd) If none of the above steps fix the problem ................................................................................................................................. 62

CONVEYOR DOES NOT RUN AFTER THE START BUTTON IS PUSHED OR AFTER A CAR IS ENTERED INTO THE TUNNELWATCH

QUEUE. ..................................................................................................................................................................................... 62

Overview: ........................................................................................................................................................................... 62

Step-By-Step: ...................................................................................................................................................................... 62 1st) Make sure the Green and Yellow communication LEDs on the Logic Card are working properly. ............................................ 62

2nd) Check the configuration of the Conveyor Enable input. ............................................................................................................. 62

3rd) Reset the conveyor enable circuit. .............................................................................................................................................. 65

4th) Check the Conveyor Enable input status on the Tunnel Status Screen........................................................................................ 65

5th) Determine that the 24 VAC source is present. ............................................................................................................................ 66

6th) Check the green STOP LED. ...................................................................................................................................................... 66

7th) Check the yellow ILOCK LED. .................................................................................................................................................. 67

8th) Check the Yellow CONV LED. .................................................................................................................................................. 67

9th) If none of the previous steps resolve the problem. ...................................................................................................................... 67

CONVEYOR DOES NOT STOP WHEN STOP BUTTON IS PUSHED. ................................................................................................... 67

Overview: ........................................................................................................................................................................... 67

Step-By-Step: ...................................................................................................................................................................... 67 1st) Check the yellow ILOCK LED and green STOP LED. ............................................................................................................... 67

2nd) If the yellow ILOCK LED doesn’t go out. ................................................................................................................................. 67

3rd) Try another Stop button. ............................................................................................................................................................. 67

4th) If all of the Stop buttons fail to turn off the yellow ILOCK LED. .............................................................................................. 67

5th) If the green STOP LED does go out and the yellow ILOCK LED still does not go out. ............................................................. 68

6th) If the yellow ILOCK LED goes out when a Stop button is pushed but comes back on as soon as the Stop Button is released. . 68

7th) If the yellow ILOCK light still comes back on as soon as the Stop Button is released. .............................................................. 68

8th) If the ILOCK and STOP LEDs operate properly when the Stop and Start buttons are used, but the conveyor still does not stop.

............................................................................................................................................................................................................ 68


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INPUT DEVICE ISSUES .......................................................................................................................................................... 68

DETECTING NO INPUTS (INPUT LIGHTS DO NOT COME ON) ON THE INPUT CARD. ...................................................................... 68

CONVEYOR DOES NOT START AUTOMATICALLY AND/OR NO PULSE OR ENTER SWITCH INPUT WHEN CONVEYOR IS FORCED ON.

................................................................................................................................................................................................. 68

THE CONVEYOR ENABLE LIGHT ON INPUT C IS NOT ON. .......................................................................................................... 68

Overview: ........................................................................................................................................................................... 68


2nd) Check the green 24v LED on the Logic Card. ............................................................................................................................ 69

3rd) If the LED is out, check wiring connections of the Input –24v and 24v COM terminals. ......................................................... 69

4th) If connections secure on bare wire (not on the insulation), use a voltmeter to check for the proper voltage. ............................. 69

5th) If there is no or low voltage then replace the affected power supply. ......................................................................................... 69

6th) If the voltage is within the proper renge then reseat the Input Card. ........................................................................................... 69

7th) If problem continues, call DRB Systems Support for more help................................................................................................. 69

DETECTING NO INPUTS IN TUNNELWATCH SOFTWARE BUT INPUT THE LIGHTS AT THE INPUT CARD ARE ON. ......................... 69

CONVEYOR DOES NOT START AUTOMATICALLY AND/OR NO PULSE OR ENTER SWITCH INPUT IN TW SOFTWARE WHEN

CONVEYOR IS FORCED ON. ........................................................................................................................................................ 69

ALL LIGHTS ON INPUT CARD WORK PROPERLY......................................................................................................................... 69

Overview: ........................................................................................................................................................................... 69


2nd) Make sure the inputs are configured correctly in Modify Setup. ................................................................................................ 69

3rd) Power off the TCS box for at Least 30 Seconds. ........................................................................................................................ 72

4th) Reseat the Input Card. ................................................................................................................................................................. 72

5th) Press the reset button on the Logic Card. .................................................................................................................................... 72

6th) Power off the TCS for 30 seconds then power it back on. .......................................................................................................... 72

7th) Check the Relay Status Screen. ................................................................................................................................................... 72

SINGLE INPUT NOT DETECTED ON THE INPUT CARD. ................................................................................................................ 73

Overview: ........................................................................................................................................................................... 73

Steps: .................................................................................................................................................................................. 73 1st) Make sure the Green and Yellow communication LEDs on the Logic Card are working properly. ............................................ 73

1st) Place a wire jumper between the COM and the input terminals for the affected input. ............................................................... 73

2nd) If the input is detected properly on the Input Card. .................................................................................................................... 73

3rd) If the input is not detected properly. ........................................................................................................................................... 73


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Read ME! Before using this Guide

Overview:

This guide is to be used to troubleshoot common problems that have been experienced installing the TunnelWatch software and Tunnel Control Station. Only use this guide if you are experiencing problems similar to the ones listed below. Note: Not all problems that you may experience are contained in this guide. If you can not associate a problem to one in this manual then call the DRB Systems Support representative for help. A DRB Systems Support representative will ask you some of the information included in this manual to determine the scope of the issue. Please try the troubleshooting steps that relate closest to the issue you are experiencing before calling.

How to Be Successful using this Guide:

This guide assumes that you have some knowledge of electrical systems, car washing equipment and the TunnelWatch Tunnel Control Station and software.

√ Refer to the issue that most closely resembles the problem you are experiencing.

√ If a section does not help, check out another section. � Example: You cannot get the Conveyor to start.

♦ You checked the Conveyor Issues, and it did not help.

♦ Check the Tunnel Devices issues.

♦ The problem may not be with the Conveyor Enable Circuit. The problem may be with the TCS relay or the Conveyor itself.

√ Use the Table of Contents as a quick reference to find the issues and the steps for each.

√ Each step of each issue MUST be completed in the order it is presented.

√ Check the operation of the equipment or process after each troubleshooting step.

√ If a step fixes the problem then stop troubleshooting unless otherwise stated.

√ If the step does not fix the problem then move on to the next step.


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Tunnel Device Issues

What to Do When A Device Does Not Turn On (Excluding the

Conveyor, Horn or Roller Up)

Overview

Troubleshooting a device that does not turn on is relatively easy. The problem is usually one of two things; either the device itself doesn’t work or it is not programmed properly in TunnelWatch.

Step-by-Step

1st) Force the device on.

1) Flip the appropriate override switch in the TunnelWatch Tunnel Control Station for the device in question to the “ON” position.

2) The green indicator light (LED) for that device should light, and the device should turn on. a) If the green LED does not turn on

i) Replace the Relay Card with a spare one or swap the card with a card from another slot.

ii) In addition, try turning the power to the Tunnel Control Station off briefly then back on. The power switch is located on the front of the Tunnel Control Station’s Power Supply.

iii) If the indicator light for the relay still does not light when forced on, contact DRB Systems Support for additional assistance.

3) If the green LED turns on but the device does not a) Check the fuse for the relay output on the Relay Card. b) Replace the Relay Card with a spare one or swap the card with a card from another

slot. c) Check to make sure the device is properly wired has water pressure, etc.

4) If the green LED and the device both turn on, flip the override switch back to “Auto” and proceed to the 2nd Step.

2nd) Force the device on from the TunnelWatch computer to verify it is

programmed properly.

1) Start the conveyor (the device may be electrically interlocked with the conveyor). 2) Type D from the TunnelWatch Master Menu, for the Device Overrides Menu.

3) A screen similar to the following screen appears:


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m

4) Use the UPARROW or DOWNARROW to place the cursor on the device you wish to

troubleshoot.

5) Use the LEFTARROW to place the diamond symbol for the device in the Force On column.

a) The correct device should turn on.

i) If it does, use the RIGHTARROW to return the diamond to the Auto ON column and

proceed to Step 3.

ii) If not, use the RIGHTARROW to return the diamond to the Auto ON column and

continue with Step 3.

3rd) Check that the device is programmed properly in TunnelWatch.

1) Type M from the TunnelWatch "Main Menu" to select the "Modify Setup Menu".

a) The following screen appears:


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2) Use the UPARROW or DOWNARROW keys to place the cursor on the “Tunnel Devices”

option.

3) Press ENTER.

a) A screen similar to the following appears:


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4) Use the UPARROW or DOWNARROW keys to highlight the device in question.

5) Press ENTER.

a) For this example, we will use the “Rust Buster” device.

• A screen similar to the following appears:


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6) Check the “Status” field. For the device to work properly, it should be set to “Active”. 7) Check that the “Relay Location” is set to the proper box, card number and relay letter. 8) Check that the “Device Position” is correct.

a) This number should be the distance the device is located from the Enter Switch. Note: The device Type (Sequential, Programmable, or Deprogrammable).

9) Press the ESC key to exit the "Tunnel Devices" screen.

a) If you are prompted “Do you want to save these changes? Y” , type Y.

4th) Check the Service Selections configuration.

1) If the device type from the 3rd step is Sequential, skip to the 5th step. Otherwise, continue with the remainder of this step.

2) Use the UPARROW or DOWNARROW keys to put the cursor on “Service Selections”

3) Press the ENTER key.



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4) Use the UPARROW or DOWNARROW keys to put the cursor on the Service that controls the

Device that is not working. a) For this example, we will use the “Rust Buster” Service.

i) If you don’t have a Service listed for this Device, press the F7 key to add one. 5) Press the TAB key once.

a) The cursor moves to the “Include Devices” column.

6) Use the UPARROW or DOWNARROW keys to place the cursor to the immediate left of the

Device (in this case, “Rust Buster”). 7) Verify that there is a checkmark to the left of the Device.

a) If not, press the SPACEBAR to put a checkmark next to it, as shown on the following

screen:


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8) Exit the Service Selections screen by pressing the ESC key.

a) If you are prompted “Do you want to save these changes? Y", type Y.

9) Use the UPARROW or DOWNARROW keys to highlight the “Button Service Selections”

option.




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11) Use the UPARROW or DOWNARROW keys to place the cursor on the Button Service that

activates the Service used to control the Device that is not working (in this example, “Rust Buster”).

12) Check that a checkmark appears in the Included column to the left of “Rust Buster”.

a) If it does not, press the TAB key.

i) The cursor moves to the Included column.

b) Use the UPARROW or DOWNARROW keys to place the cursor to the left of “Rust Buster”

c) Press the SPACEBAR to add the checkmark.


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13) When you’re finished, press the ESC key.

a) If you are prompted “Do you want to save these changes? Y” , type Y.

14) Press the ESC key to exit the "Modify TunnelWatch Setup" menu.

• A screen similar to the following appears:


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15) Use the UPARROW or DOWNARROW keys to highlight the “Invoke Changes” option


17) Press the ENTER key again to begin the invoke process.

18) Once the tunnel and queue are clear, TunnelWatch makes the changes and the TunnelWatch Main Menu returns.

5th) Did the change help?

1) If the device still does not work, contact DRB Systems Support for more assistance.

What to do When Devices Do not Turn On at the Correct Time

Overview

If your tunnel devices are turning on and off, but not when they should, you can take several troubleshooting steps to rectify this problem. Almost all timing problems are caused by TunnelWatch not knowing where the vehicle is in the tunnel. This can have several causes, and these causes and their solutions are discussed in the steps that follow.

Step-by-Step

The most common cause of timing problems is that the Pulse Switch or Enter Switch is not working properly.

√ The inputs for these two switches are located on Input Card #1 in Tunnel Control Station #1.


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√ The Enter Switch is normally wired to Input 1B.

√ The Pulse Switch to Input 1A.

1st) Check the Enter Switch.

1) The Enter Switch Input (1B) green indicator light (LED) should illuminate as soon as a vehicle passes in front of or over the Enter Switch.

2) The green LED should go out as soon as the vehicle leaves the Enter Switch. a) If the Enter Switch LED turns on or off too soon or too late, or is always on or always

off, the problem could be the Input, the Enter Switch itself, or the wiring. b) If the LED never turns on.

i) Check to make sure the input works by using a short piece of wire to jumper the COM and 1B terminals together. (1) These terminals are located on the upper left terminal strip in the Tunnel

Control Station. ii) The LED should turn on.

(1) If the LED turns on, the input is good, and you should try some of the additional suggestions for fixing the enter switch or wiring at the end of this section.

(2) If the LED does not turn on then move the Enter Switch wire from the 1B terminal to an unused input terminal (1F or higher). (a) Check to make sure this input works by using a short piece of wire to

jumper a COM terminal and the new input terminal together. (i) The LED for this input should turn on.

(A) If the LED does not turn on then call DRB Systems Support to replace the Input card.

(B) If the LED is ON then change the TunnelWatch software settings to match the new Input number.

3) If the LED never turns off. a) Try temporarily disconnecting the wire from the 1B terminal. b) The LED should turn off.

i) If it does, the input is good and you should try some of the additional suggestions for fixing the Enter Switch or wiring at the end of this section.

ii) If the LED does not turn off then move the enter switch wire from the 1B terminal to an unused input terminal (1F or higher) (1) If the LED switches on and off appropriately with the activation/deactivation of

the Enter Switch then change the TunnelWatch software settings to match the new Input number

(2) If the LED turns on and stays on then there may be a problem in the wiring of the device. You should try some of the additional suggestions for fixing the wiring at the end of this section.

4) If the LED turns on and off, but not at the right times, or if the input tested OK in one of the previous tests, the problem is likely in the wiring or Enter Switch itself. a) Check to make sure the wires are properly connected to the COM and 1B terminals on

the upper left terminal strip in the Tunnel Control Station. b) Try cleaning the Enter Switch or adjusting its sensitivity. c) If you cannot locate the problem with the Enter Switch, contact your electrician or

tunnel equipment supplier for further help.

2nd) Check the Pulse Switch.

1) The Pulse Switch input (1A) green indicator light (LED) should flash on and off in a steady, regular pattern whenever the conveyor is running.


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2) If the LED never turns on. a) Check to make sure the input works by using a short piece of wire to jumper the COM

and 1A terminals together on the upper left terminal strip in the Tunnel Control Station.

b) The LED should turn on. i) If it does, the input is good and you should try some of the additional suggestions for

fixing the Pulse Switch or wiring at the end of this section. ii) If the LED does not turn on then move the Pulse Switch wire from the 1A terminal

to an unused input terminal (1F or higher). (1) Check to make sure this input works by using a short piece of wire to jumper a

COM terminal and the new input terminal together. (a) The LED for this input should turn on.

(i) If the LED does not turn on then call DRB Systems Support to replace the Input card.

(ii) If the LED is ON then change the TunnelWatch software settings to match the new Input number.

3) If the LED never turns off. a) Try temporarily disconnecting the wire from the 1A terminal. b) The LED should turn off.

i) If it does, the input is good and you should try some of the additional suggestions for fixing the Pulse Switch or wiring at the end of this section.

ii) If the LED does not turn off then move the Pulse Switch wire from the 1A terminal to an unused input terminal (1F or higher). (1) If the LED switches on and off appropriately with the activation/deactivation of

the Pulse Switch then change then the TunnelWatch software settings to match the new Input number.

(2) If the LED turns on and stays on then there may be a problem in the wiring of the device. You should try some of the additional suggestions for fixing the wiring at the end of this section.

4) If the indicator light does not flash on and off steadily (misses a pulse, gets two pulses quickly back-to-back, etc.), or the input tested OK in one of the previous tests, the problem is most likely the Pulse Switch or wiring. a) Check to make sure the wires are properly connected to the COM and 1A terminals on

the upper left terminal strip in the Tunnel Control Station. b) Check to make sure the Pulse Switch is properly mounted and that there are no

foreign objects interfering with the switch. c) Check the Pulse Switch for problems, and replace it if necessary.

3rd) See how the TunnelWatch software tracks a vehicle

1) Once any problems with the Enter Switch and Pulse Switch have been resolved, verify that TunnelWatch knows were the vehicle is in the tunnel by checking the "Queue and Wash Display": screen.

2) To view the "Queue and Wash Display", type Q from the Tunnel Watch Main Menu. A screen similar to the following appears:


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3) The "Queue and Wash Display" screen is easy to understand if you think of the double solid line as your enter switch. Vehicles above the double solid line on the screen have been programmed but have yet to enter the tunnel. Vehicles below the double solid line are already in the tunnel. Vehicles move from above the double solid line to below the double solid line when they pass in front of or over the Enter Switch. When a vehicle exits from the tunnel, it disappears from the screen.


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The screen below is typical of the information normally shown on the "Queue and Wash Display":

4) In the screen above, Q1 is a vehicle that has been programmed at the tunnel entrance

terminal and has yet to enter the tunnel. This means the vehicle is in the queue or stack of cars waiting to enter the tunnel. W1 and W2 are both vehicles that are currently in the tunnel being washed. Notice that TunnelWatch is aware of how long each vehicle is and precisely where the front of the vehicle is in the wash. Also, notice the arrow to the right of W2. When the arrow is pointing at W2, the Service Selections box lists the services this vehicle is scheduled to receive.

a) Use the UPARROW or DOWNARROW keys to move the arrow to the other vehicles.

5) If both the Enter and Pulse Switches are working properly, the "Queue and Wash Display" should match exactly to what is taking place in your tunnel. a) If it does not, check your Enter and Pulse Switches for proper operation.

Note: The second most common reason TunnelWatch becomes confused about where a vehicle is located in the tunnel is that its Simulated Pulse or Simulated Enter features have been turned on.

4th) Check that the Simulated Pulse and Simulated Enter switch are active.

1) If either or both are turned on and your Pulse and Enter Switches are working properly, turn them off. a) These emergency features are not to be designed used when your Enter or Pulse

Switches are working properly. b) You should only use them in case your Enter Switch, Pulse Switch, or both fail.

2) To see if the Simulated Enter and/or the Simulated Pulse switches are on. Look for the scrolling message at the bottom of any TunnelWatch screen. See the following example.


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3) If the above messages appear, turn off these features.

4) Type O for the "Other Operations Menu" when you are at the TunnelWatch Main Menu.

The following screen appears:


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5) Press the UPARROW or DOWNARROW keys to highlight Enter Switch Simulation Is ON.

6) Press the ENTER key to switch the ON message to OFF.

7) Press the UPARROW or DOWNARROW keys to highlight Pulse Switch Simulation Is ON.

8) Press the ENTER key to switch the ON message to OFF.


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5th) Check the Pulse Distance.

1) If device-timing problems persist, the final detail to check is TunnelWatch’s pulse distance. a) The “Average Pulse Length” number is the average distance the conveyor travels in

one pulse. b) The pulse distance number is used by TunnelWatch to convert the pulses sent to

TunnelWatch into feet and inches that you can more easily understand. c) If the pulse distance is set incorrectly, TunnelWatch will not know where the vehicle

actually is located in the tunnel and will not know its correct length. 2) If any of the following situations pertain to your situation then follow the 4th step to re-

measure the pulse distance. a) If the number is too low, services will turn on behind the vehicle. b) If the number is too high, services will turn on before the vehicle. c) This problem progressively gets worse the further the vehicle travels down the tunnel.

3) If none of the above situations pertain to what is happening in the tunnel, go to the 6th step. Note: The DRB Systems Support representative will ask you for the results of each of the previous troubleshooting steps. They may ask for the information from the following steps as well. Please have this information ready.

4) Follow the below process to re-measure the Pulse Switch: a) To reduce human reaction time error, slow the conveyor to a crawl.

♦ About one foot of travel distance every five seconds b) Open the TCS door and locate the input light associated with the Pulse Switch on the

Input Card (Should be input 1A.) c) Find the conveyor device relay (should be Relay 1A) d) Force the relay on using the override switch.

♦ The LED for the Pulse Switch input should be blinking on the Input Card. Note: You may have to press the conveyor Start button to energize the Conveyor Enable Circuit. e) Ask someone to manually kick up a roller.

♦ As an alternative, you could kick up a roller in the TCS box by forcing ON the "roller up" relay for several seconds, then turn it OFF.

f) Stop the conveyor when the pulse light is on by forcing the conveyor relay to the OFF position with the override switch. (It may take a few tries to get it right.)

g) Go into the tunnel and mark the track where the roller is positioned. h) Force ON the conveyor and count 20 pulse light activations. i) Stop the conveyor again exactly on the 20th pulse light activation. Note: The pulse should be blinking at a regular pace. Any erratic or irregular pulse signals could indicate a pulse switch problem. j) Mark the track where the roller is now positioned. k) Measure the distance (in inches) between the two marks that you made on the track. l) Divide by 20. This is the "pulse length". m) Write this down for reference. n) Repeat steps d through l four more times so you have a total of five "pulse length"

measurements. o) Discard the highest and lowest numbers. p) Add the three remaining measurements together and divide by 3 to get the "average

pulse length". q) Write this down.


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5) Update the pulse distance setting in the TunnelWatch software.

a) Type M from the TunnelWatch Main Menu for the "Modify Setup Menu". The following

screen appears:

6) Press the UPARROW or DOWNARROW keys until the “Tunnel Related Inputs” screen is

highlighted

7) Press the ENTER key and a screen similar to the following is displayed.y


07/13/17 25

8) Press the ENTER key until the “Average Pulse Length” field is highlighted.

9) Type the figure you recorded from the above device measurement. a) Use the + key to increase the measurement by one hundredth of an inch per press. b) Use the - key to decrease the measurement by one hundredth of an inch per press


07/13/17 26

10) Press the ESCAPE key when the Average Pulse Length number is correct. The following

box appears on the screen:

11) Type Y to save the changes.

12) Press the ESCAPE key. The following box appears on the screen:

13) Press the DOWNARROW key to place the cursor on the “Invoke Changes” option.


15) Press the ENTER key again and once the tunnel and conveyor are clear, TunnelWatch

invokes the changes and returns to the Main Menu.

6th) Call DRB Systems Support.

1) If none of the above steps have solved the problem, contact DRB Systems Support for more help.

Note: The Support representative will ask you for the results of each of the previous troubleshooting steps. Please have this information ready.


07/13/17 27

Communications Issues

What To Do When a “Stations No Response” or “RRS Comm

Intermittent” Message appears

Overview

The “Stations No Response” or “RRS Comm Intermittent” message appears at the bottom of the TunnelWatch display whenever the TunnelWatch software is unable to talk to the Tunnel Control Stations properly. As long as this situation exists, TunnelWatch cannot wash vehicles. Make sure to use the Tunnel Control Station relay override switches to operate your tunnel equipment until this problem is resolved.

Step-by-Step

1st) Verify TunnelWatch is running version 3.2.1 or higher.

1) Look at the TunnelWatch Main Menu (shown below).

√ The version number is located in the upper-right corner of the screen.

√ TW 2.12 or higher is required to communicate with a Tunnel Control Station.

√ If you are not running version 2.12 or higher, you will need to update to a compatible version.

• Call DRB Systems Support for information and the files necessary to update your TunnelWatch software version.


07/13/17 28

2nd) Check the TunnelWatch System Status Screen.

1) Press ALT+S to bring up the System Status screen (shown below).

√ In the lower half of the screen you will see a listing for each of the Tunnel Control

Stations connected to the system. 2) Check for the following for each station:

√ Address: = TCS: 01 through 04

√ Model: = 2

√ Version: = 1.6 (or higher)

√ SerialNum #: = (assigned by the ROM chip on the Logic Card, could be most any number other than all zeros)

√ Success%: = 100.00% 3) If any of the above statues are not as indicated, above then TunnelWatch is not receiving

information back from the TCS. a) yIf the Success% is climbing and eventually reached 100%, the problem was most

likely a temporary interruption in communications. b) If the problem reoccurs or the Success% never reaches 100%, continue

troubleshooting.

4) Press ESC to exit this screen and return to the TunnelWatch Main Menu.

3rd) Check for the proper Relay Station(s) Port Assignment

1) Press M from the TunnelWatch Main Menu, for the Modify Setup menu.

2) Use the UPARROW or DOWNARROW keys to place the cursor on the “General

Configuration” option

3) Press the ENTER key. The following screen appears:


07/13/17 29

4) Press the F6 key for the Serial Comm screen. The following screen appears:


07/13/17 30

5) Use the UPARROW key to place the cursor on the Relay Station(s): field.

a) This field should be set to 3 (Serial Port 3) as shown above.

i) If this setting does not appear, type 3 at this option.

ii) If the setting does appear go to step 6. b) If the stations are connected to Port 4 of the TunnelWatch communications computer

card the port assignment should read 4 (Serial Port 4).

i) If this setting does not appear, type 4 at this option.

ii) If the setting does appear then go to step 6.

6) Press ESC to return to the Serial Communications screen.

7) Once you are finished, press ESC to exit.

8) Press Y if you are prompted Do you want to save these changes? Y. 9) You will be returned to the Modify Setup menu.

10) Press the ESC key. The following box appears on the screen:

11) Press the DOWNARROW key to place the cursor on the “Invoke Changes” option then

press the ENTER key.

12) Press the ENTER key again and once the tunnel and conveyor are clear, TunnelWatch


4th) Check the TCS and Record the Station Configuration settings.

1) Go to the Tunnel Control Station(s). 2) Check to make sure the Tunnel Control Station is turned on and has power.

a) The power switch is on the front of the power supply located in the bottom left of the Tunnel Control Station enclosure.

3) Make sure it is in the On position. 4) Turn the Power Switch to the Off position for approximately 5 minutes then turn the switch

back to the On position. a) This step will allow the internal breaker to reset.

5) If the switch is On but the light does not come on, check the fuse. a) The fuse is located under the 110v AC input wiring terminals. b) Pull out the plastic fuse holder to expose the 2A 250v glass inline fuse. c) Replace the fuse if necessary.

6) Check the circuit breaker which is providing power to the Tunnel Control Station to make sure it has not been tripped, reset it if necessary.

7) Check to make sure the 110v AC power is reaching the site input wiring terminals. 8) If power is reaching the terminals, but the station will not power on, replace the Power

Supply with a replacement unit from DRB Systems. a) Contact DRB Systems Support for an RMA and shipping.

9) Check the Yellow Receive LED on the Logic Card. a) The light will blink if there is power to the card, some form of RS-422/485 signal, and

the card is not damaged.


07/13/17 31

b) If the LED is not blinking then there is either no power, the RS-422/485 signal is absent or the card is damaged.

i) Go to step 10. c) If the LED is blinking, an RS-422/485 signal is reaching the TCS. The problem is most

likely in the TCS unit. i) Stay at the TCS unit and go to the 12th Step - Check the Logic Card Settings.

10) Record the setting of the Address Selector Rotary Switch on each Logic Card; do not rely on the Digital Readout on the card. a) Make sure that each Logic Card is set to a unique address number and that these

addresses are in sequence starting at 1.

11) Once you know the address settings for each station, compare them with the software settings. a) Type M from the Tunnel Watch Main Menu for the Modify Setup menu.

b) Use the UPARROW or DOWNARROW keys to place the cursor on the “Station


c) Press the ENTER key. A screen similar to the following appears:

d) Compare the address settings for each station with the Station Number listed for each

station. e) Make sure each Station Type is set to Tunnel Control Station. f) If any of the software settings are different than the physical address settings, make the

appropriate changes so that they match.

g) Once you are finished, press ESC to exit.

h) Press Y if you are prompted "Do you want to save these changes? Y". i) You will be returned to the Modify Setup menu.


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j) Press the ESC key. The following box appears on the screen:

k) Press the DOWNARROW key to place the cursor on the “Invoke Changes” option then

press the ENTER key.

l) Press the ENTER key again and once the tunnel and conveyor are clear, TunnelWatch


5th) Reconfigure the system using the Config.bat configuration program.

1) Contact DRB Systems Support for assistance in using this utility.

6th) Check the BIOS Settings for the type of PC used at the site.

1) Contact DRB Systems Support to obtain a copy of the correct settings for the type of PC in use at your site.

7th) Check the RS- 422/485 I/O card, cables and connectors.

1) Look at the back of the PC and locate the card with the labels "TW Port r" and "TW Port q".

2) Make sure the DB9 to RJ connector is firmly connected to the communications card. See the documentation included with the computer for model-specific part numbers.

3) Make sure that the green Jumper Cable connects into the DB9 to RJ connector and to then to the communications phone jack labeled TCS.

4) Check the wiring of the communications phone jack by removing the cover. a) Record the color of each wire and the color of the terminal that each is connected.

i) Example: the White/Orange wire is connected to the Green terminal. b) Go out to the TCS Unit. c) Using the following wiring diagram for reference:

i) Determine the appropriate terminal in the TCS unit for each of the colored wires. ii) Example: The White/Orange wire is connected to the Green terminal of the TCS

phone jack in the office. This wire should be connected to the TX- terminal in the TCS unit.

iii) Use this example to trace the other 3 wires. iv) Correct any wiring problems then recheck the communications.

Note: The bare shield wire should be connected to one of the SH terminals in the TCS unit ONLY.


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Shield/Ground

(1) Reference only - - Wiring must be installed by a qualified licensed electrician and must conform to allcodes. Your configuration and requirements may differ.

DRB Systems is not responsible for the installation, maintenance, or safety of your electrical wiring.

(2) Leave 2 to 3 feet slack in the RS-422 cable to allow future maintenance.

(3) Part numbers. Warning: Avoid Quick Connect phone jacks when using stranded wire.

RJ-12, 6-wire phone jack, surface mount: PJ00350 (DRB Systems)5C381 (Grainger)

RJ-12, 6-wire phone jack, flush mount: 6C069 (Grainger)

RS-422 cable (shielded twisted pairs): CA05422 (DRB Systems)1212C or 1292 or 2466C (Alpha)9502 or 1419A or 8723 (Belden)C0890 or C0601 or C1352 (Carol)4A635 or 4A639 or 2W985 (Grainger)

Typical Tunnel Control Station Communication Wiring

RS-422 cable

(2,3)TunnelWatch

PC

6-wire phone jackMount within 6 feet of PC

Orange/White

White/Orange

White/Blue

Blue/White

1st pair

2nd pair

Orange/WhiteWhite/Orange

White/BlueBlue/White

Note: Use CN09210adapter at PC for

Quatech RS-422 cards

Black Blue Green

RedYellow White

RX-SH

1I1J1K1L1M

TX-

COM

COM

COM

COM

RX+TX+

SH

5) Move the DB9 to RJ connector with the green Jumper Cable to "TW Port r" computer

board. 6) Change the port assignment in the TunnelWatch software.

a) Press M from the TunnelWatch Main Menu for the Modify Setup menu.

b) Use the UPARROW or DOWNARROW keys to place the cursor on the “General


c) Press the ENTER key. A similar screen to the following appears:


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d) Press the F6 key for the Serial Comm screen. A similar screen to the following

appears:


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e) Use the UPARROW key to place the cursor on the Relay Station(s): field.

f) Type a 4 to change the setting to 4 (Serial Port 4). g) Once you are finished, press ESC to exit.

h) Press Y when you are prompted Do you want to save these changes? Y. i) You will be returned to the Modify Setup menu.

j) Press the ESC key. The following box appears on the screen:

k) Press the DOWNARROW key to place the cursor on the “Invoke Changes” option.

l) Press the ENTER key.

m) Press the ENTER key again and once the tunnel and conveyor are clear, TunnelWatch


8th) Swap the DB9 to RJ connector and Jumper Cable.

Note: The DB9 to RJ connector and the green telephone style Jumper Cables were shipped in a white box labeled Spare Parts. See the TunnelWatch Computer Installation Instructions for help in identifying and replacing these parts.


07/13/17 36

1) Disconnect the DB9 to RJ black communications connector from the back of the computer.

2) Disconnect the green telephone style Jumper Cable from the back of the DB9 to RJ connector and the phone jack labeled TCS.

3) Connect the DB9 to RJ communications connector to the computer card. See the documentation included with the computer for model-specific port numbering.

4) Connect the green telephone style Jumper Cable into the back of the DB9 to RJ communications connector and the phone jack labeled TCS.

9th) Remove the TunnelWatch communications computer from the PC and

check for proper configuration.

Note: This step requires the computer to be opened and a computer card removed. Please do not try this step unless you have some experience with computer equipment. Call the DRB Systems Support for help. They will provide you with the precautions and assistance needed to perform this step.


07/13/17 37

1) Use the following diagram and table to confirm the jumper and DIP switch settings and correct them if necessary.

a) If the settings are correct put the card back in to the computer and go to the 11th step. b) If the settings are not correct, match the settings to the diagram and put the card back

in to the computer. 2) Recheck the communications. 3) If the communications are not back to 100% then move onto the 11th step.

10th) Check the Logic Card settings.

1) Go back out to the TCS box (if you are not already there). 2) Turn the power off to the TCS unit. 3) Pull firmly but gently on the side brackets of the Logic Card (top most card) to remove it. 4) Find the red JP1 (Watchdog) jumper located near the metal bracket at the front of the

card.

♦ See the following diagram for location of this jumper.

Jumper setting for the 2 port cards: J1A through J2A - P, P, and T closed. L and L open. J1B through J2B - AT,RT, and NE open. J1C through J2C - DIV1 and DIV2 open. DIV4 closed. The two headers for RS422 must be covered and the two RS232 headers must be uncovered.


07/13/17 38

5) Ensure that the jumper is covering both metal pins. a) If this jumper is not present, call DRB Systems Support for help.

6) Find the black JP2 (Communications) jumper located near the black 20-Pin connector at the back of the card.

♦ See the following diagram for the location of this jumper. 7) Ensure that this jumper is properly installed:

a) Count the number of wires on the RX+, RX-, TX+ and TX- communications terminals located in the TCS box on the upper right terminal strip.

b) If each of these terminals has a single wire attached then this jumper should be ON. c) If each of these terminals has TWO wires attached then this jumper should be OFF

(covering only one pin). 8) If the jumper is missing and there are single wires in the communications terminals then

call DRB Systems Support for more help.

9) Plug the Logic Card back into the TCS unit. 10) Turn the power to the TCS unit ON. 11) Reset the Logic Card.

a) Press the recessed RESET button with the tip of a pen, pencil, or small screwdriver blade. See the previous drawing for the location of this switch.

b) After a brief internal reset and power on self-test, the Logic Card will resume attempting to communicate with the TunnelWatch system.

11th) Perform a continuity test on the communications wiring.

1) Ensure there are no shorts or broken wires in the RS422/485 cable. Note: You must disconnect the RS422/485 wires at both ends of the cable to be able to properly check the continuity.

12th) Perform a TCS unit Self-Test.

1) Set the Address Selector Rotary Switch on the Logic card to position 0 (zero). 2) Press and release the RESET button.

a) If the Logic card is working, the Relay Output card LEDs will cycle through a set of patterns.

b) Interpret the light pattern using the following Interpreting the TCS Unit Reset Light Pattern chart.

c) Follow the appropriate instructions for the type of result that you see from the Self-test.

JP2 - Communications Jumper

JP1 - Watchdog Jumper

TCS Logic Card

RESET Button Address Selector


07/13/17 39

Interpreting the TCS Unit Reset Light Pattern ♦ If all four lights for one card fail to turn on for any of the light sequences, the relay card may

be bad.

♦ If one, two or three of the lights from one or more Relay Cards fails to turn on for any of the light sequences then those individual relays may be at fault.

♦ If one or more vertical columns of lights (all the A’s or B’s etc.) fail to light for any of the light sequences, the Logic Card is faulty.

♦ If any of the above situations occur intermittently throughout the light sequences then the problem is most likely with the Logic Card.

3) Ensure the results of the self-test. a) Re-do the self-test using the above steps.

4) If a Relay Card or the Logic Card is found to be faulty then call DRB Systems Support for help.

5) If the correct pattern cycle occurs for both tests then set the Logic Card back to normal: a) Set the address switch to 1 (or whatever its normal address is). b) Press and release the RESET button. c) The TCS will resume its normal state.

13th) If all the steps of this process fail.

1) If the TCS unit still will not communicate properly with the TunnelWatch software then call DRB Systems Support for more help.

Self-Test Relay Output Card LED Lighting Pattern:

Sequence 0 Sequence 1 Sequence 2 Sequence 3




RELAY CARD Red LED's

































































07/13/17 40

Keypad Issues

Key(s) on the Keypad are not Functioning Properly

Overview:

During the Installation Testing procedures you are asked to check the functionality of each Tunnel Entrance Keypad key. If the key shows the "ERR. UNDEFINED KEY!" message on the display, then use the following to resolve the problem.

Step-By-Step

1st) Ensure the expected key assignments have been assigned to the correct

keys.

1) Determine the key(s) position on the Keypad overlay grid.

2nd) Check the Keypad configuration of the TunnelWatch software.

1) Press M from the TunnelWatch Main Menu to access the Modify Setup menu.

2) Press the DOWNARROW key to highlight the "Keypad Configuration - (Entrance Keypad

Button Setup)" option. Note: This option is not visible on the initial Modify Setup menu screen. Continue

pressing the DOWNARROW key to scroll the screen until the option is available.


07/13/17 41

3) Press ENTER.

a) A screen similar to the following will appear. i) If the screen does not display as shown:

(1) Press the TAB or F3 key until all 96 keys are visible.

(2) Skip to step19 to save the change and re-check the operation of the key(s).

4) Use the ARROW keys (Up, Down, Left, Right) to select the key that is not functioning

correct. Note: A programmed key has a period or colon to the left of the key number.

5) Press ENTER to add the correct program to the Primary Function.

•The following box appears with the Function Types.


07/13/17 42

6) Press an arrow key to highlight the Type of key to add.

Note: See the Keypad Configuration section of the TunnelWatch Controller System Manual for descriptions of the key Types and key functions.

7) Press ENTER.

a) A box similar to the following is displayed with the choices of functions for each type.


07/13/17 43

8) Use an arrow key to highlight the desired function to add.

9) Press ENTER.

a) The function will be displayed in the Primary Function box, and the cursor will move to the Secondary Box field.


07/13/17 44

10) Repeat steps 9-12 to program the Secondary Function if needed.

11) Press ENTER when completed.

a) The cursor will move to the "Printed Overlay Format" box. 12) Type the name for the key, if one is not present, on one or more of the lines in this box.

• Hints for using this box:

♦ The printed display for the key will look better if everything is centered and there are some spaces left before and after each line.

♦ Press the F3 or TAB key to center all the text after you are finished entering all

your text on all the lines.

♦ To cut the text on a line, press the F8 key.

♦ To paste this line on another line, move to the new line and press F7.


07/13/17 45

♦ To copy the text shown in the "Desc:" field of the Primary and the Secondary Function boxes, press the F9 key.

• See the example in the following screen.

13) Press the ESCAPE key to finishing editing the key.

14) Move to the next key to change. 15) Print a new overlay description page if you changed any descriptions.

a) Press the F2 key to begin printing the overlay.

b) Press ENTER to start the printing.

16) When you are finished, press the ESCAPE key.

17) Type Y to save the changes. The following screen appears:


07/13/17 46

18) Press the Y key to accept the changes.

Note: If you decide that the changes are not acceptable then press the N key and all your changes are erased.

19)

20) Press the ESCAPE key. The following box appears over the Modify TunnelWatch Setup

menu.

21) Press the DOWNARROW key until you highlight the “Invoke Changes” option.


23) Press the ENTER key again.

♦ If the tunnel is empty, TunnelWatch invokes the changes and returns to the TunnelWatch Master Menu.

♦ If the tunnel is not empty, TunnelWatch waits for the tunnel to clear, invokes the changes and then returns to the TunnelWatch Master Menu.

3rd) Contact DRB Systems Support

1) If the key(s) still will not function properly then call DRB Systems Support for more help.


07/13/17 47

Tunnel Entrance Keypad Doesn’t Work

Overview

This section covers problems that may occur when installing the Tunnel Entrance Keypad Terminal. This troubleshooting section assumes that the keypad has never worked. If the keypad has worked, the information in this section IS valid, but the troubleshooting steps may differ. There are two separate issues that may occur when powering on the keypad for the first time.

♦ First the keypad displays "ATTEMPTING DOWNLOAD".

• This means the keypad is receiving power from the TunnelWatch computer but is not receiving a valid communication signal.

♦ Second the keypad display is blank.

• This typically means the keypad is not receiving 12VDC power from the TunnelWatch computer.

Step-By-Step

1st) Connect the Keypad Terminal directly to the back of the TunnelWatch

Computer.

1) Unplug the keypad cable from the Outdoor Phone Jack. 2) Take the Keypad terminal and the attached black keypad cable to the TunnelWatch

computer office. Note: If the keypad is mounted on the wall, remove the four nylon screws securing the base to the keypad.

3) Unplug the green, telephone style, communications jumper from the black communication connector labeled CN09011. Note: See the TunnelWatch Computer Installation Instructions for help identifying the connector and cables.

4) Ensure that the black communication connector labeled CN09011is connected to the computer port labeled "Serial Port A". a) If not connected to "Serial Port A", move the connector to this port.

5) Plug the black keypad cable connected to the Keypad into the black communication connector labeled CN09011. a) If the terminal has no display at all, proceed to the 5th Step. b) If the keypad has a display but displays "ATTEMPTING DOWNLOAD", go to the 2nd

Step. c) If the keypad beeps then displays "LOADED TERM TYPE 2D", the problem is in the

RS 422 communications cable, the wiring of the phone jack labeled "Tunnel Entrance" or the wiring of the Outdoor Phone Jack.

i) Recheck the wiring of the phone jack labeled "Tunnel Entrance and the wiring in the Outdoor Phone Jack using the TCS Installation Instructions Guide.

ii) Repair or replace the jacks or wiring as needed.

2nd) Check the TunnelWatch software to verify that the configuration for the

terminal is correct.

1) Press M from the TunnelWatch Main Menu to access the "Modify Setup" menu. The following screen appears:


07/13/17 48

2) Use the DOWNARROW key to move the cursor down the screen until it highlights the

“General Configuration” option

3) Press the ENTER key. A screen similar to the following appears:


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4) Press the F6 key for the "Serial Comm" menu. The a screen similar to the following

appears:


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5) Check the setting of “Entrance Keypad #1:”

a) It should be set for “A (PC Com1 IRQ4)”. b) If it is set to anything else, change it back to option “A”.

i) Type A to enter an “A” in this field.



8) Press the ESCAPE key once. The following box appears on the screen:

9) Press the DOWNARROW key until the cursor highlights the “Invoke Changes” option.


• If the tunnel is empty, TunnelWatch invokes the changes and returns to the TunnelWatch Main Menu.

• If the tunnel is not empty, TunnelWatch waits for the tunnel to clear, invokes the changes, and then returns to the TunnelWatch Main Menu.

3rd) Connect a spare keypad cable to the tunnel entrance terminal.

Note: A spare keypad cable was shipped in a white box labeled Spare Parts.


07/13/17 51

1) Unplug the keypad cable from the black communication connector labeled CN09011on the back of the computer.

2) Disconnect the black cable from the back of the Keypad. Note: See the label on the back of the Keypad for directions on disconnecting this cable.

3) Reconnect the spare cable to the Keypad. 4) Plug the black keypad communications cable into the black communication connector

labeled CN09011 on the back of the computer.

4th) Move the Keypad Connector to Serial Port 2.

1) Unplug the 12-volt power supply from the black communication connector labeled CN09011.

2) Disconnect the black communication connector labeled CN09011 from Serial Port A. 3) Reconnect the black communication connector labeled CN09011 to the computer port

labeled "Serial Port B". 4) Plug the 12-volt power supply in to the black communication connector labeled CN09011. 5) Press M from the TunnelWatch Main Menu to access the "Modify Setup" menu. The

following screen appears:


“General Configuration” option



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8) Press the F6 key for the "Serial Comm" menu. A screen similar to the following appears:


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9) Press the UPARROW key until Entrance Keypad #1 field is highlighted.

10) Press B (must be a capital B) to change the setting to "B (PC Com2 IRQ3)".


12) Type Y to save the changes. 13) Press the ESCAPE key once. The following box appears on the screen:





16) The Keypad should beep then display "LOADED TERM TYPE 2D". a) If the keypad still does not show this then call DRB Systems Support for more help. b) If the display does show this then take the keypad back out to the tunnel entrance and

reconnect to the Outdoor Phone Jack.

5th) Check the 12-volt power supply that powers the Keypad.

1) Locate the black communication connector labeled CN09011 found on the back of the computer.

2) There should be a small, black wire (like a Walkman headphone jack) plugged into the side, top or bottom of this connector. a) This is the 12-volt power supply TunnelWatch uses to power the tunnel entrance

terminal. 3) Verify that the 12-volt supply's electrical outlet is working properly. 4) Replace the 12-volt power supply with a spare.

Note: A spare 12-volt power supply was shipped in a white box labeled Spare Parts. 5) If the Keypad still does not display "LOADED TERM TYPE 2D" then call DRB Systems

Support for help.

6th) If none of the above troubleshooting steps resolve the issue.

1) Call DRB Systems Support for more help.

Conveyor Enable Circuit

Problems with the Conveyor Enable Circuit During TCS Installation

Overview

Use the suggestions given for one or more of the below issues to troubleshoot the Conveyor Enable Circuit. This section directly relates to the 12th Step of the Tunnel Control Station Installation Instructions.


07/13/17 54

Each step of the Conveyor Enable Test section (12th Step) of the Tunnel Control Station Installation Instructions is listed below. Find the step that you are having trouble with and perform the troubleshooting instructions.

Conveyor Enable Test Troubleshooting Issues:

1st) Turn the Conveyor Relay (1A) in the TCS box to the OFF position.

2nd) If the Green 24v LED is OFF.

1) Check the 5-Ampere fuse on the Conveyor Enable board. a) If blown, replace it. b) If it blows again, a short circuit exists in the Stop, Start, or conveyor wiring.

2) Check to make sure the 24VAC Power Supply is on. a) Check the breaker or the outlet this power supply is connected to.

3) Check the wiring of the Conveyor Enable Circuit NEUT and PWR terminals. a) Ensure that your 24VAC power supply is wired properly.

i) See the 6th Step of the Tunnel Control Station Installation Instructions for the Conveyor Enable Wiring Diagram.

3rd) If the Green STOP LED is OFF.

1) If the green STOP LED is not on and the green 24V LED is on, a) Check the Stop switches and wiring. b) All unused STOP terminals on the Conveyor Enable Circuit board should have a

jumper from the A to the B terminals, if wired using the standard wiring instructions. c) All your STOP buttons have to be Normally Closed buttons. d) Check for a bad or irregularly wired STOP button(s).

i) If the recommended "Home Run" wiring technique was used: (1) Using a piece of copper wire to short the 1A terminal to the 1B terminal:

(a) If the green STOP LED comes on the problem is in the Stop switch #1 wiring or switch.

(b) If not, move on to terminals 2A and 2B and so on until all Stop switches have been checked.

ii) If the “Daisy Chain” method of wiring was used, isolation to the offending switch is more difficult. (1) Consult the electrician to test these buttons and the wiring.

2) If the green STOP LED is not on and green 24V LED is not on then see the 1st Step (The Green 24v LED is OFF). Note: The green 24v and STOP LED's HAVE to be on before trying following steps.

4th) Press and release a Start button.

1) The green 24v LED on the Conveyor Enable Circuit board did not stay on. a) This would only happen when the conveyor circuit is wired improperly. b) Make sure all the wiring is identical to the wiring diagrams found in the Conveyor

Enable Circuit Wiring step of the Tunnel Control Station Installation Instructions. 2) The green STOP LED on the Conveyor Enable Circuit board did not stay on.

a) If the green STOP LED is not on and the 24V LED is on, i) Check the Stop switches and wiring. iii) Check for a bad or irregularly wired STOP button(s).

3) If the green STOP LED is not on and the green 24V LED is not on then see the 1st Step (The green 24v LED is OFF).

4) The yellow ILOCK LED of the Conveyor Enable Circuit board did not turn on. a) If the yellow ILOCK LED does not come on, a Start button is at fault.


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i) Try another Start button. b) If none of the Start buttons work then use a wire jumper to connect between the

terminals 1A and 1B on the Start Terminal block. i) If the yellow light does not come on replace the 24VAC double pole double throw

relay on the Conveyor Enable card. ii) If replacing the relay does not fix the problem then replace the Conveyor Enable

Card. 5) The green LED for the conveyor enable input (1C) in the Tunnel Control Station did not

turn on. a) If the green 24v and STOP LED's are on:

i) Check the relay on the Conveyor Enable Circuit board. ii) If this relay is ok, then the problem is with the internal wiring of the TCS unit.

(1) Call DRB Systems Support for help. b) If one or both of the green 24v and STOP LED's are OFF then refer to the appropriate

step of this section.

5th) Press and hold a Stop button.

1) The green 24v LED on the Conveyor Enable Circuit board did not stay on. a) This would only happen when the conveyor circuit is wired improperly. b) Make sure all the wiring is identical to the wiring diagrams found in the Conveyor

Enable Circuit Wiring section of the Tunnel Control Station Installation Instructions.

2) The green STOP LED on the Conveyor Enable Circuit board did not turn off. a) At the very least, this STOP button is wired incorrectly or the button is broken. b) If the STOP buttons are wired in a Daisy Chain then other buttons may be at fault too.

3) The yellow I Lock LED of the Conveyor Enable Circuit board did not turn off. a) At the very least, this STOP button is wired incorrectly or the button is broken. b) If the STOP buttons are wired in a Daisy Chain then other buttons may be at fault too.

4) The green LED for the conveyor enable input (1C) on the Input Card did not turn off. a) If all previous conditions of this step are successful then one of the following may have

occurred: i) The Conveyor Enable Input wires have been moved. ii) Another power source has been wired to the input terminal 1C.

b) If any of the previous conditions have failed then refer to that step to fix the problem first then continue to the next step.

6th) Release the Stop button.

1) The green 24v LED on the Conveyor Enable Circuit board did not stay on. a) The only situation where this could happen is when one of the previous steps failed.

i) Go back to the 1st Step of this testing procedure. 2) The green STOP LED on the Conveyor Enable Circuit board did not turn back on.

a) The only situation where this could happen is when one of the previous steps failed. i) Go back to the 1st Step of this testing procedure.

3) The yellow I Lock LED of the Conveyor Enable Circuit board did not stay off. a) At the very least, this STOP button is wired incorrectly or the button is broken or stuck

START button. b) If the STOP buttons are wired in a Daisy Chain then other buttons may be at fault too.

4) The green LED for the conveyor enable input (1C) in the Tunnel Control Station did not stay off. a) If all previous conditions of this step are successful then one of the following may have

occurred:


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i) The Conveyor Enable Input wires have been moved. ii) Another power source has been wired to the input terminal 1C.

b) If any of the previous conditions have failed then refer to that step to fix the problem first then continue to the next step.

7th) Press and hold in a Stop button and a Start button together.

1) The green 24v LED on the Conveyor Enable Circuit board did not stay on. a) The only situation where this could happen is when one of the previous steps failed.

i) Go back to the 1st Step of this testing procedure. 2) All other Conveyor Enable Circuit LEDs is not off.

a) The STOP Buttons are wired wrong. i) This is especially true for the Daisy Chain STOP/START button wiring methods.

3) The Conveyor Enable Input (1C) green LED is not off. a) If all previous conditions of this step are successful then one of the following may have

occurred: i) The Conveyor Enable Input wires have been moved. ii) Another power source has been wired to the input terminal 1C.

b) If any of the previous conditions have failed then refer to that step to fix the problem first. Then continue to the next step.

8th) Press and release a Stop button

9th) Turn the override switch for the Conveyor Relay (1A) to the ON position

1) Conveyor is turning on. a) Ensure that the control voltage wiring to the motor control contactor is wired correctly

i) See the Conveyor Enable Circuit Wiring Diagram of the Tunnel Control Station Installation Instructions. (1) The control wire for the conveyor motor control contactor must be connected

to the CONV terminal of the Conveyor Enable Circuit board. (2) Only the RED wire from the Conveyor Enable Circuit should be connected to

the relay source terminal 1A. (3) Only the GREY wire to the Conveyor Enable Circuit should be connected to

the relay control voltage terminal 1A NO. (4) There should NOT be any wires from relay 1A directly connected to the

conveyor motor control contactor. b) Ensure that the conveyor motor control contactor is not malfunctioning or is turned ON.

10th) Press and release a Start button.

1) The conveyor did not start. a) Ensure that the override switch for relay 1A is in the ON position.

i) The switch will not work in the AUTO position until the TCS unit is connected and communicating successfully to the TunnelWatch software.

b) Ensure that the conveyor motor control contactor is not malfunctioning or is forced OFF.

c) Test the conveyor operation from the conveyor motor control center. i) If the conveyor will start from this system then recheck the wiring of the Conveyor

Enable Circuit. d) Check the Conveyor Enable Circuit wiring diagram to ensure that the circuit is wired

correctly.

11th) Press and release a Stop button.

1) The conveyor did not stop. a) Ensure that the control voltage wiring to the motor control contactor is wired correctly.


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i) See the Conveyor Enable Circuit Wiring Diagram of the Tunnel Control Station Installation Instructions. (1) The control wire for the conveyor motor control contactor must be connected

to the CONV terminal of the Conveyor Enable Circuit board. (2) Only the RED wire from the Conveyor Enable Circuit should be connected to

the relay source terminal 1A. (3) Only the GREY wire to the Conveyor Enable Circuit should be connected to

the relay control voltage terminal 1A NO. (4) There should NOT be any wires from relay 1A directly connected to the

conveyor motor control contactor. b) Ensure that the conveyor motor control contactor is not malfunctioning or is turned ON.

12th) The Conveyor Enable Circuit does not respond as indicated

1) If you cannot get any of the Conveyor Enable Circuit lights to respond as indicated in the Testing the Conveyor Enable Circuit section of the Tunnel Control Station Installation Instructions and the above steps did not help.


Irregular Start/Stop Button Wiring Issues

3 or 4 Wire Daisy Chain Stop/Start Button Issues

Overview:

One of these two situations may be occurring: 1. There are no stop buttons pushed in, and the green 24v LED is on. When any start

button is pushed, the green STOP and yellow ILOCK LEDs turn on, but as soon as the Start button is released, these LED's turn off.

2. The Start buttons work even though a Stop Button was pushed in. This situation usually indicates a problem with the Stop/Start button wiring. The STOP and START buttons are wired in a daisy chain using three or four wires, and some or all of the these wires are connected to the wrong Stop/Start terminals on the Conveyor Enable Circuit board. To identify these wires use the following troubleshooting steps.

Step-By-Step

1st) Disconnect all 3 wires.

1) Be sure all the stop switches are out.

2nd) Find the two wires that have continuity.

1) The remaining wire should go to Start terminal 1A (or any Start A terminal).

3rd) Push in a stop and then a start button.

4th) Measure continuity between the Start terminal (1A or any Start A

terminal) and one of the two remaining wires.

1) You may or may not have continuity on this wire.

5th) Measure continuity between the Start terminal (1A or any Start A

terminal) and the other wire.

1) You may or may not have continuity on this wire.

6th) You should get continuity on only one of the two wires.

7th) Connect the wire that has continuity to STOP terminal 5B.


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8th) Connect the wire that does not have continuity to the STOP terminal

labeled I-LOCK.

9th) If this does not correct the problem OR two pairs of wires have

continuity during any of the above steps.

1) The stop/start buttons are wired incorrectly. 2) Refer to the 3-Wire STOP/START Button wiring diagram in the Tunnel Control Station

Installation Instructions to correct.

Conveyor Issues

Conveyor Won't Start

Overview

There are a number of reasons why your conveyor might not run when you expect it to. Sometimes the problem is TunnelWatch. Other times the problem lies with a piece of equipment at your carwash that has malfunctioned in some way. This section is designed to provide you troubleshooting techniques you can use to quickly determine why your conveyor won’t run.

Step-By-Step

1st) Try the Stop/Start buttons

1) Press a Stop then a Start button for the conveyor in your tunnel. 2) Reprogram the vehicle and try again. 3) If the conveyor still refuses to run, go to the 2nd Step.

2nd) Check the other stop buttons for your conveyor in your tunnel.

1) A different stop button may have been pressed without your knowledge or one of your stop buttons might be stuck.

2) If the conveyor still won’t run, go to the 3rd Step.

3rd) Check the Conveyor Enable Input LED

1) Check the green indicator light (LED) for Input C on Input Card #1 in Tunnel Control Station #1. a) If the LED is lit, the problem probably is with TunnelWatch or with a tripped circuit

breaker. Proceed to the 4th Step. b) If the LED is not lit, the problem is most likely in your Stop/Start buttons, fluid level

sensors, or air pressure sensors i) Check the Start/Stop buttons again. ii) Take the cover off each one and make sure the wires are attached and not

corroded. iii) Make sure there is no moisture in the stop/start buttons. iv) Make sure to check the fluid levels in your conveyor motor and any other safety

switches wired into the Conveyor Enable Circuit. Note: Electricians will often wire the fluid level switches and other safety switches so that they act like stop buttons making the LED go out when they are tripped.

4th) Check the Conveyor Relay LED.

1) Check the green LED for the conveyor relay (pre-wired to Relay 1A in Tunnel Control Station #1).

2) If the green LED for Relay 1A is NOT lit: a) Force the relay on by moving the override switch to the “ON” position.


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i) The green LED should light. ii) The conveyor should run if the green LED for Relay 1A is lit and the green LED for

Input 1C in Tunnel Control Station #1 is lit. iii) If the conveyor does not run and both lights are lit, proceed to the next step.

b) If the green LED for Relay 1A does not light when you place the override switch in the “ON” position, there might be a problem with your TunnelWatch hardware.

c) Replace Relay Card #1 with another Relay Card. i) Turn power to the TCS unit off. ii) Using the winged brackets of Relay Card #1, pull the card outward from the unit. iii) Using the winged brackets of any other Relay Card, pull the card outward from the

unit. iv) Place the second Relay Card into the slot for Relay Card #1. v) Turn the power to the TCS unit back on.

d) Repeat step b. i) If the indicator light for the conveyor relay still does not light when forced on, contact

DRB Systems Support for additional help.

5th) Check the conveyor electrical connections to the TCS Unit

1) Check and reset your circuit breakers and low fluid level switches, if all three of the following conditions are met: a) The green LED for Relay 1A is lit b) The green LED for Input 1C in Tunnel Control Station #1 is lit c) The conveyor still will not run.

2) It is very likely there is an electrical or mechanical problem in your carwash that is keeping your conveyor from running. a) Contact your electrician or your tunnel equipment installer for further help.

6th) Check the configuration for the Auto On feature of TunnelWatch

1) If you can force the conveyor on at the relay station, but it doesn’t work properly when sending cars, then check the TunnelWatch setup.



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“Conveyor, Idle and Horn Control” option



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5) Match each of the following fields to the proper settings.

a) Conveyor Output Relay Location: Box - 1 Relay 1A b) Switch Type: - N/Open c) Auto-Start: - On Send Car d) Conveyor Delay Before On(sec): - 3.0 e) Auto "Off" Delay(sec): - 15.0

6) If any of these settings are different on your system, complete the following steps.

a) Press ENTER to highlight the field that needs changed.

b) Press F10 to access a list of available options. i) If the field requires a number, simply type the appropriate number

ii) Press ENTER.

c) Press an arrow key to highlight the desired option. d) Press ENTER to select the option.






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2nd) If none of the above steps fix the problem


Conveyor does not run after the Start button is pushed or after a

car is entered into the TunnelWatch queue.

Overview:

This problem will usually occur when a vehicle is programmed into the tunnel for the first time, or when the Start Button is pressed to start the conveyor for the first time after the TunnelWatch computer is installed. Once this issue is resolved and you have more problems starting the conveyor then see the Conveyor Won't Start Issue of this section.

Step-By-Step:

1st) Make sure the Green and Yellow communication LEDs on the Logic Card

are working properly.

1) See the Communications Issues section of this manual for help determining that 100% communications has been established between the Logic Card and the TunnelWatch software

2nd) Check the configuration of the Conveyor Enable input.

1) Make sure the input is set up for the correct Box number and Input letter (should be 1 C) in the TunnelWatch software.



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3) Use the DOWNARROW key to move the cursor down the screen until it highlights the “Station

Configuration - (Define Stations Connected to the System)” option


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5) Match each of the following fields for the Conv Enable Input.

a) Switch Box: - 1 b) Input: - 1C c) Type: - N/Open

6) If any of these settings are different on your system complete the following steps.

a) Press ENTER to highlight the field that needs changed

b) Type the appropriate number, letter or N until the N/Open setting is displayed.

c) Press ENTER.








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3rd) Reset the conveyor enable circuit.

1) Press a STOP Button then press a START Button.

4th) Check the Conveyor Enable input status on the Tunnel Status Screen.

1) Press T from the TunnelWatch Main Menu to access the "Tunnel Status" screen. a) A screen similar to the following will display.

2) If the "Conv Enable" filed does not show an asterisk:

a) Try forcing the conveyor ON in the software. i) Press D from the TunnelWatch Main Menu. ii) A screen similar to the following displays.


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iii) Use an arrow key to highlight the CONVEYOR device.

iv) Press the LEFTARROW key to place the indicator in the "Force ON "column.

b) If the conveyor does not run, try forcing the conveyor ON at the TCS Relay Card (should be relay 1 A).

i) If the conveyor still does not run, the problem is probably in the conveyor starter, wiring, or the conveyor motor itself go to the next step.

c) If the conveyor does run, the problem is probably in the TunnelWatch software setup. i) Call DRB Systems Support for help.

5th) Determine that the 24 VAC source is present.

1) Check the green 24V LED. a) If it is lit, 24 VAC is present. b) If it is not lit, check the 5 Ampere fuse on the Conveyor Enable board. c) If blown, replace it.

i) If it blows again, a short circuit exists in the Stop, Start, or conveyor wiring.

6th) Check the green STOP LED.

1) It will be lit if all Stop switches and the associated wiring is working properly. 2) If the green STOP LED is not on and the green 24V LED is on, check the Stop switches

and wiring. a) If the recommended wiring technique was used, each Stop switch wire pair comes to

its own terminals on the Conveyor Enable board. i) Using a piece of copper wire, short the 1A terminal to the 1B terminal.

(1) If the green STOP LED comes on, the problem is in the Stop switch #1 wiring or switch.

(2) If not, move on to terminals 2A and 2B and so on until all Stop switches have been checked.


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b) If the “Daisy Chain” method of wiring was used, isolation to the offending switch is more difficult.

i) Consult the electrician to test these buttons and the wiring.

7th) Check the yellow ILOCK LED.

1) It should light and stay lit when a Start switch is pushed then released, if the green 24v and Stop LEDs are lit. a) If the yellow ILOCK LED does not come on, a Start button is at fault.

i) Try another Start button. b) If none of the Start buttons work then use a wire jumper to connect between the

terminals 1A and 1B on the Start Terminal block. i) If the yellow ILOCK LED light does not come on, replace the 24VAC double pole

double throw relay on the Conveyor Enable card. (1) If replacing the relay does not fix the problem then replace the Conveyor

Enable Card. 2) Once the yellow ILOCK LED is lit, the electrical interlock requirements are met, and power

is available to all interlocked tunnel devices.

8th) Check the Yellow CONV LED.

1) If it is not lit then use the section for troubleshooting a single relay to check the function of relay 1A.

2) If it is lit, and the conveyor does not start: a) The problem is with the wiring from the TCS to the Conveyor Starting Contactor, the

Contactor, or the conveyor itself (or its wiring).

9th) If none of the previous steps resolve the problem.


Conveyor does not stop when Stop button is pushed.

Overview:

This issue may only occur for one of the following reasons: 1. During the installation process, the Conveyor Enable Circuit Testing Step (the 12th Step) of

the Tunnel Control Station Installation Instructions was not completed correctly. 2. The conveyor circuit wiring has been altered after the test was completed. 3. A separate wiring problem was introduced concerning the motor control center or relay 1A of

the Tunnel Control Station. Follow the below troubleshooting process to resolve this situation.

Step-By-Step:

1st) Check the yellow ILOCK LED and green STOP LED.

1) The yellow ILOCK LED should go out and stay out when a Stop Button is pushed and released.

2nd) If the yellow ILOCK LED doesn’t go out.

1) A Stop button may be at fault.

3rd) Try another Stop button.

4th) If all of the Stop buttons fail to turn off the yellow ILOCK LED.

1) Check to see if the green STOP LED goes out when all Stop buttons are pushed. 2) If the green STOP LED does not go out

a) The Stop button wiring is the problem.


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b) Correct the wiring per the Tunnel Control Station Installation Instructions.

5th) If the green STOP LED does go out and the yellow ILOCK LED still does

not go out.

1) The Conveyor Enable Relay may be at fault. a) Remove the Conveyor Enable Relay. b) If the yellow ILOCK LED still does not go out

i) Disconnect the wires to the CONV and INTLK terminals on the Conveyor Enable Circuit Board.

ii) �f the yellow ILOCK LED goes out. (1) The problem is in the Conveyor Enable Circuit wiring. (2) Most likely, there is a 24v source connected to one of these terminals.

iii) If the yellow ILOCK LED still does not go out, it is possible (however unlikely) that the Conveyor Enable Circuit Board is bad. (1) Call DRB Systems Support for more help.

iv) If the yellow ILOCK LED does go out, replace the Conveyor Enable Relay.

6th) If the yellow ILOCK LED goes out when a Stop button is pushed but

comes back on as soon as the Stop Button is released.

1) The problem may be bad/shorted Start Button or the Start Button wiring. a) Check the Start buttons and wiring and repair as needed.

7th) If the yellow ILOCK light still comes back on as soon as the Stop Button

is released.

1) The problem may be the Conveyor Enable Circuit Board. a) Call DRB Systems Support for more assistance.

8th) If the ILOCK and STOP LEDs operate properly when the Stop and Start

buttons are used, but the conveyor still does not stop.

1) Remove the Conveyor Enable Relay. a) If the conveyor still runs

i) The problem is in the conveyor motor, starter, or other external wiring. b) If the conveyor stops

i) Call DRB Systems Support for more assistance.

Input Device Issues

Detecting no inputs (input lights do not come on) on the Input

Card.

Conveyor does not start automatically and/or no pulse or enter

switch input when conveyor is forced on.

The Conveyor Enable light on input C is not ON.

Overview:

This troubleshooting process combines many problems that may be a result of the TCS box not detecting input device signals. During the TCS installation, you have been instructed to test for proper detection of each of the input devices and test the Conveyor Enable Circuit. If one of these input signals is not detected then use this process. If none of the input device signals are detected then use the Detecting No Inputs issue that follows.


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Step-By-Step:




2nd) Check the green 24v LED on the Logic Card.

3rd) If the LED is out, check wiring connections of the Input –24v and 24v

COM terminals.

4th) If connections secure on bare wire (not on the insulation), use a

voltmeter to check for the proper voltage.

1) Look for 24 to 28 VAC if you are using the TCS internal Power Supply. 2) If using a transformer you supplied, look for 16v AC/DC.

5th) If there is no or low voltage then replace the affected power supply.

6th) If the voltage is within the proper renge then reseat the Input Card.

7th) If problem continues, call DRB Systems Support for more help.

Detecting no inputs in TunnelWatch software but input the lights

at the Input Card are ON.

Conveyor does not start automatically and/or no pulse or enter

switch input in TW software when conveyor is forced on.

All lights on Input Card work properly.

Overview:

This troubleshooting process is typically used when programming cars for the first time after the installation of the TunnelWatch computer. This process may be needed if inputs have been added or software changes have been made.

Step-By-Step:




2nd) Make sure the inputs are configured correctly in Modify Setup.

1) Press M from the TunnelWatch Main Menu to access the "Modify Setup" menu. The

following screen appears:


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2) Use the DOWNARROW key to move the cursor down the screen until it highlights the “Tunnel

Related Inputs” option



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4) Check the Box number and Input letter for each of the Input Devices configured for your

system. a) Each Input Device should have a "1" for the Switch Box field. b) The Enter, Pulse and Conv Enable Input Devices should have the same number/letter

combination as the above screen. i) Any exceptions to this should be noted in the Installation Document shipped with

your computer. c) If any of the Input number/letter or Switch Box: numbers are not correct:

i) Press ENTER to highlight the field that needs to be changed.

ii) Type the number, or letter and number of the correct setting into the field.

iii) Press ENTER to move to the next field.







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3rd) Power off the TCS box for at Least 30 Seconds.

4th) Reseat the Input Card.

1) See the 13th Step of the Communications Issues section of this guide.

5th) Press the reset button on the Logic Card.

1) Press the recessed reset button with the tip of a pen, pencil, or small screwdriver blade. 2) After a brief internal reset and power on self-test, the Logic Card will resume attempting to

communicate with the TunnelWatch system.

6th) Power off the TCS for 30 seconds then power it back on.

7th) Check the Relay Status Screen.

1) Type E at the TunnelWatch Main Menu. A screen similar to the following is displayed.

2) Check the status of the Inputs and Relays.

a) If the inputs are not listed and the relays are listed or the inputs are listed and the status of the inputs do not change.

• To view the rest of the inputs press the DOWNARROW key to scroll down.

• A dot or asterisk next to the Input Device in the ON LIGHT column indicates the statuses.

i) Call DRB Systems Support for more help. b) If both inputs and relays are not listed, and "RRS COMM INTERMITTENT" and/or

"STATIONS NO RESPONSE" are not scrolling across the bottom of the screen. i) Call DRB Systems Installation Support for more assistance.


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Single input not detected on the Input Card.

Overview:

This troubleshooting process is usually used when testing for proper detection of each of the inputs during the TCS Installation. This section may also be used if an input fails after the initial tests were completed successfully.

Steps:




1st) Place a wire jumper between the COM and the input terminals for the

affected input.

2nd) If the input is detected properly on the Input Card.

1) The problem is with the external device or wiring.

3rd) If the input is not detected properly.

1) The input is bad. 2) Rewire to another input and change software configuration or replace the Input Card.

a) Call DRB Systems Support if more help.

Documents

Tunnel Control Station Installation Troubleshooting Guide€¦ · 04/01/2017 · TunnelWatch TCS Installation Troubleshooting Guide 6 07/13/17 Read ME! Before using this Guide Overview: