DRB-Tunnel Related Inputs

Overview 

The Tunnel Related Inputs screen provides the configuration for Tunnel Control Station inputs, including the conveyor and relays. Many of the fields require data that must be obtained by measuring and timing various parts of the carwash equipment.

Pulse Switch

Real-time pulse switch activation can be monitored from the INPUTS box on the Operations screen. While pulse switch input activation can also be monitored from the TCS STATUS box, that information is updated approximately once per second, which means that it may not display pulse switch input activations when the interval between inputs is less than 1 second (0.5, for example).

This section outlines an overview of the configuration, for more in depth troubleshooting refer to the "Pulse Switch Troubleshooting" document.

*Note: The most important setting in TunnelWatch is Average Pulse Length! All device timing relies on it.

*Note: Pulse Switch Debounce Is Time-Based. Some debounce values in TunnelWatch are distance-based while others are time-based. The pulse switch debounce value is measured in seconds.

Box/Input

Select the address of the Tunnel Control Station and relay to which the pulse switch device is actually wired. If you only have one Tunnel Control Station, select 1 for the address; if you have more than one Tunnel Control Station, you will need to determine which one the device is wired to and select that (typically box 1).

*Note: The pulse switch is normally wired/configured as input A (on card 1) in the Tunnel Control Station.

Switch Type

Select the pulse switch's polarity: Normally Open or Normally Closed.

*Note: The pulse switch is typically wired as a normally open switch.

*Note: all relays turn off regardless of switch type setting:

• Anytime the TunnelWatch computer loses power;

• Anytime the Tunnel Control Station loses power; and

• Every day, briefly at midnight when the TunnelWatch computer automatically restarts.

Debounce

When the metal contacts in a switch connect, multiple signals can be generated. This phenomenon is called bouncing. The Debounce parameter ensures that TunnelWatch only registers one enter pulse signal, even if it receives more than one before the number of seconds configured here. 

Set the debounce value to as close to 0 (zero) as possible, for example, 0.1. Setting this to 0 disables the debounce function.

Average Pulse Length

This is the most critical measurement of the entire tunnel. It is the average distance the conveyor travels between pulses. This field accepts decimal inches.

• Measure this distance using the following method described in the "Measuring the Pulse Distance" document.

• Sites should only ever need to re-measure the pulse (and update this setting) if physical changes to the pulse switch are performed, such as changing the type of pulse switch or conveyor sprocket.

Desired Pulse Accuracy

This determines the maximum inaccuracy between device activations. The normal value should be between 1 to 6 inches. This field defaults to 1". Do not change this without consulting with a facilities.

Minimum Pulse Time

This is the number of seconds after a pulse switch closure that TunnelWatch will not accept a new pulse input. This is used to debounce the pulse switch.

• This value should be no more than 1/2 of the average time between pulses.

• A value of 0.5 is good for most pulse switches.

• A 0 (zero) in this field disables the debounce logic.

 TunnelWatch can work with wide pulses and still deliver services accurately. The optimum pulse interval is between .5 to 5 seconds.

Maximum Pulse Time

This is the maximum number of seconds that can elapse between two pulses before the action selected in the When Pulse Fails setting (see below) is performed. A value of 0 (zero) disables this feature.

• Set this value to 3 times the average number of seconds that elapses between pulses.

Pulse Monitoring

This parameter determines what TunnelWatch does if it detects a missing pulse. There are two choices.  

• Assume Roller Jam: This is the default. TunnelWatch pauses its internal pulse interpolation if the pulse switch input is not received by the average pulse time. This keeps TunnelWatch in sync with the vehicles in the tunnel when a roller jams. TunnelWatch resumes normal operations if the pulse is received before the time set in the Maximum Pulse Time field, described later. If the pulse is not received, the conveyor may be turned off.

• Assume Pulse Switch Failure: If the time between pulse inputs is approximately an even multiple of the average time between pulses, TunnelWatch assumes that the pulse switch is intermittent and automatically corrects for the missing pulses. In addition, the error message PULSE SW. INTERMITTENT is displayed on the screen.

When Pulse Fails

This parameter determines what TunnelWatch does if it doesn't receive a pulse signal within the number of seconds entered in the Maximum Pulse Time field (see above). This field has four choices.

• Do Nothing: The conveyor continues operating, without advancing the services. TunnelWatch indicates either a roller jam or pulse switch failure depending on the Pulse Monitoring setting (see above).

• Idle Conveyor: Activates the conveyor idle device, configured on the Idle tab of the Conveyor, Idle, Horn setup screen, to stop the conveyor's movement.

• Stop Conveyor: This is the default. The conveyor stops.

• Simulate Pulse: TunnelWatch assumes the pulse switch has failed and automatically simulates the pulse switch.

Enter Switch

This section outlines an overview of the configuration, for more in depth troubleshooting refer to the "Enter Switch Troubleshooting" document.

The enter switch, or photo eye, is a set of lenses that send and receive a laser input from one side of the tunnel track to the other.  When a vehicle is present between the eyes the line of site between the sensors is broken and TunnelWatch detects the presence of a vehicle and begins to measure.  

Real-time enter switch activation can be monitored from the INPUTS box or the virtual TUNNEL on the Quick Status or Production screens, or from the INPUTS box on the Operations screen.

• Enter Switch Debounce Is Distance-Based. Some debounce values in TunnelWatch are distance-based while others are time-based. The enter switch debounce value is measured in feet and inches.

• Set A Vehicle Length For Enter Switch Simulation. Configure the Maximum Vehicle Length parameter to ensure that wash and extra services are applied to the entire vehicle, for every vehicle, when enter switch simulation is active.

Box/Input

Select the address of the Tunnel Control Station and relay to which the enter switch device is actually wired. If you only have one Tunnel Control Station, select 1 for the address; if you have more than one, you will need to determine which one the device is wired to and select that.

*Note: The enter switch is normally wired/configured as input B (on card 1) in the Tunnel Control Station.

Switch Type

Select the pulse switch's polarity: Normally Open or Normally Closed.

*Note: The enter switch is typically wired as a normally open switch.

*Note: all relays turn off regardless of switch type setting:

• Anytime the TunnelWatch computer loses power;

• Anytime the Tunnel Control Station loses power; and

• Every day, briefly at midnight when the TunnelWatch computer automatically restarts.

Debounce

When the metal contacts in a switch connect, multiple signals can be generated. This phenomenon is called bouncing. The Debounce parameter ensures that TunnelWatch only registers one enter switch signal, even if it receives more than one before the conveyor has traveled the distance configured here.

Enter Switch & Empty Queue

This parameter controls what happens if the enter switch is activated, but there aren't any vehicles in the queue. There are four choices:

• Stop Conveyor: The conveyor motor stops running.

• Idle Conveyor: The conveyor motor continues running, but disengages from the conveyor.

• Measure Vehicle: This is the default value. TunnelWatch measures the vehicle. *Note a vehicle sent this way will get the default wash service (a Rapid or basic wash).

• Wait For Queue: TunnelWatch ignores the enter switch activation until a vehicle is inserted into the queue.

Minimum Vehicle Length

The enter switch measures a vehicle's length based on continuous, unbroken activity from the enter switch. The Minimum Vehicle Length parameter is the minimum distance for which the enter switch must be continuously activated before TunnelWatch will identify the enter switch activity as being caused by a vehicle. This prevents TunnelWatch from identifying prep staff (who might activate the enter switch while spraying a vehicle) as a vehicle. A vehicle must be this long in order to receive a wash.

This parameter also requires that the current vehicle be at least this far into the switch before the next vehicle can be programmed and sets the window of opportunity to adding any traits to the current vehicle, once this distance is met you can no longer send any programming functions for that car.

*Note: 5' is a reasonable value to enter here.

Maximum Vehicle Length

A warning is generated if a vehicle is longer than this parameter. The vehicle still receives its services for its entire length regardless of this value.

During simulated enter switch operation, this value defines the length of every vehicle. See the related Length of Vehicle Before Switch Failure is Reported field for additional information.

*Note: 25' is a reasonable value to enter here.

Length of Vehicle Before Switch Failure Is Reported

An enter switch failure is generated if a vehicle measure this long or more. When this happens, TunnelWatch immediately uses the Maximum Vehicle Length value as the length for the remainder of the time the vehicle is in the tunnel.

*Note: 35' is a reasonable value to enter here.

Average Vehicle Length

This measurement is used with the Space Between Vehicles measurement (configured below) to calculate the conveyor speed, which is then used to calculate the Conveyor Speed cars/hr figure (the INPUTS box) and Util % figure (the TUNNEL PRODUCTION box) on the Production screen.

*Note: 17' is a reasonable value to enter here.

Space Between Vehicles

The average distance between a vehicle's rear bumper and the next vehicle's front bumper. This measurement is used with the Average Vehicle Length measurement (configured above) to calculate the conveyor speed, which is then used to calculate the Conveyor Speed cars/hr figure (the INPUTS box) and Util % figure (the TUNNEL PRODUCTION box) on the Production screen.

*Note: 3' is a reasonable value to enter here.

Tunnel Exit Distance

This parameter determines when TunnelWatch stops tracking a vehicle in the tunnel. It is the distance from the enter switch to the tunnel exit. TunnelWatch tracks the rear of each vehicle against this distance. Once the rear of a vehicle reaches this point, TunnelWatch stops tracking the vehicle.  *Note this setting also affects the anti collision configuration for TW Exit style setups.

Vehicle Position

This parameter is used to calculate a vehicle's position when the enter switch is simulated. It is the distance from the front (or rear) of the vehicle relative to the enter switch when a roller is issued.

Conveyor

Box/Input

Select the address of the Tunnel Control Station and relay to which the conveyor device is actually wired. If you only have one Tunnel Control Station, select 1 for the address; if you have more than one, you will need to determine which one the device is wired to and select that.

*Note The conveyor is normally wired/configured as conveyor card (on input card 1) in the Tunnel Control Station.

In addition to the conveyor card location, a list of the wireable stop circuit inputs can be found on this tab.  These are simply name fields to help identify which stop is activated on the conveyor board and display that name if the stop is triggered on the error read out screen. 

Tire Switch

The tire switch determines the distance between the front and rear of the vehicle where the tires should be for specific chemical applications.  As a vehicle progresses through the enter switch and is measured the passenger front and rear tires come into contact with the switch triggering an input for both front and rear tire locations allowing TunnelWatch to activate devices based on this measurement.

Real-time tire switch activation can be monitored from the INPUTS box or the virtual TUNNEL on the Quick Status or Production screen, or from the INPUTS box on the Operations screen.

• Tire Switch Debounce Is Distance-Based. Some debounce values in TunnelWatch are distance-based while others are time-based. The tire switch debounce value is measured in feet and inches.

Box/Input

Select the address of the Tunnel Control Station and relay to which the tire switch device is actually wired. If you only have one Tunnel Control Station, select 1 for the address; if you have more than one, you will need to determine which one the device is wired to and select that. 

*Note: The tire switch is normally wired/configured as input D (on input card 1) in the Tunnel Control Station.  If the site does not have a tire switch, set the box to 0 (zero).

Switch Type

Select the tire switch's polarity: Normally Open or Normally Closed.

*Note: The tire switch is typically wired as a normally open switch.

*Note: all relays turn off regardless of switch type setting:

• Anytime the TunnelWatch computer loses power;

• Anytime the Tunnel Control Station loses power; and

• Every day, briefly at midnight when the TunnelWatch computer automatically restarts.

Debounce

When the metal contacts in a switch connect, multiple signals can be generated. This phenomenon is called bouncing. The Debounce parameter ensures that TunnelWatch only registers one tire switch signal, even if it receives more than one before the conveyor has traveled the distance configured here.

Tire Switch Position

This is the tire switch's distance from the enter switch. The tire switch can be placed before or after the enter switch. However, the tire switch must be positioned so that front and rear tires activate it while the enter switch is activated. This distance must also allow for any delay times or distances that are set for the enter switch.

Tire Switch Error Checking

This parameter allows TunnelWatch to detect errors in the enter switch and tire switch by requiring the tire switch to be activated twice while the car is in the enter switch. If the tire switch is not positioned properly, false errors can occur. Therefore, be sure that the enter switch's debounce logic completes before the tire switch is activated.

• To troubleshoot a device that is not activating properly based on tire position first inspect the input for activation of the tire switch as the vehicle progresses, a failure to activate as the car is measured would indicate an issue with the switch or input wiring itself and should be check by a facilities technician.

  • If the input appears to be functioning, check the vehicle in the production tab and note if it lists the location of 'Tire 1' and 'Tire 2'

    • If the distances appear for the tires, the switch is working proprely, contact your IT technician to check the programming of the device that is not working properly.

    • If the distances do not appear, contact your facilities technician to troubleshoot the input switch and wiring.

VPD

The Vehicle Profile Detection feature detects open truck beds and then dynamically controls the services applied to them

Real-time Vehicle Profile Sensor activity can be monitored from the INPUTS box on the Operations screen.

Sensor Interface Type

This setting determines if you are connecting to the older style (network) unit or the newer style (serial) unit.  At this time all WhiteWater sites utilize the newer serially connected unit. 

Sensor Port

Determines the location on the serial interface board that the VPD is connnected to.  This will either be serial port 5 or 6. 

Sensor Position

The distance, in feet and inches, between the Vehicle Profile Sensor device and the enter switch. If the Vehicle Profile Sensor device is directly in line with the enter switch, enter 0'. 

Select After Enter Switch or Before Enter Switch based on the position of the Vehicle Profile Sensor device relative to the enter switch. If the Vehicle Profile Sensor device is directly in line with the enter switch, it doesn't matter which option you select.

Sensor Height

The distance - in feet and inches - between the bottom of the Vehicle Profile Sensor device and the floor below it.  If the Vehicle Profile Sensor device is installed, powered, connected to TunnelWatch, and has an unobstructed path straight down to the floor, select Measure Height to make the Vehicle Profile Sensor device measure the distance and automatically enter it here.

Other Inputs

In general, WhiteWater only utilizes the 'Auto Roller' fucntion that is preconfigured on this tab.  The 'Send Car' and 'Roller Locator' options are not typically used. 

Auto Roller

The Auto Roller input is a dedicated tire switch (located immediately after the roller-up door) that automatically issues a roller after each wheel activation, or optionally only for the rear wheel. The sensor is disabled in the software until a standard roller is raised. This allows the vehicle's front tire to pass over the sensor without raising the rollers. After the standard set of rollers is raised, the vehicle is pulled by the front tire until the rear tire activates the sensor. At this time any activation of the switch will activate a set of extra rollers behind the rear wheel as safety rollers in case the first set of rollers are "jumped." Note that the roller pacing system is disabled when using Automatic rollers because a set of standard rollers is not issued.

Box

Select the address of the Tunnel Control Station and relay to which the auto roller input is actually wired. If you only have one Tunnel Control Station, select 1 for the address; if you have more than one, you will need to determine which one the device is wired to and select that.

If the site does not have an auto roller input, set the value to 0 (zero).

Input

Select the input inside the Tunnel Control Station to which the auto roller input is actually wired.

The inputs depend on whether 1 or 2 cards are installed in the Tunnel Control Station.

• 1A, 1B, 1C, 1D, 1E, 1F, 1G, 1H, 1I, 1J, 1K, 1L, 1M, 1N, 1O, 1P

•  2A, 2B, 2C, 2D, 2E, 2F, 2G, 2H, 2I, 2J, 2K, 2L, 2M, 2N, 2O, 2P

If the site does not have an auto roller input, set the value to 0 (zero).

Type

Select the auto roller input's polarity: Normally Open or Normally Closed.

*Note: The auto roller input is typically wired as a normally open input.

Debounce (Feet)

When the metal contacts in a switch connect, multiple signals can be generated. This phenomenon is called bouncing. The Debounce parameter ensures that TunnelWatch only registers one auto roller input signal, even if it receives more than one before the conveyor travels the number of feet configured here.