Virtual Positioning System Retrofit Kit

Kit Installation Manual Virtual Positioning System Retrofit Kit 1MANUL-KT113 REV 03 Belanger, Inc. * P.O. Box 5470 * Northville, MI 48167 Customer Service Phone (248) 347-4700 * Fax (248) 380-9681

Belanger, Inc. Virtual Positioning System Retrofit Kit

Table of Contents Operational Warning...2 Important Safety Information...3 Safety Symbols and Signal Words...3 Introduction...4 Overview...4 Parts Included...4 Installation...5 Photo Eye Placement...5 Shuttle Home Target...7 Shuttle Home Proximity Switch...8 Width Sonar...9 Utility Connections...10 Software...11 Initial Startup...11 Before You Begin...11 Understanding the Virtual Positioning System...11 Initial position before machine motion begins.... 12 During initial positioning, system locates front of vehicle and then sizes the width.... 13 After the width has been sized, machine must butterfly in front to start cycle.... 14 After the initial butterfly in front on the vehicle, the machine is in its Normal Wash Cycle... 15 Initial position before machine motion begins.... 16 1MANUL-KT113 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1

Operational Warning Formulations containing the chemicals listed below are particularly dangerous and should not be used even at low concentrations: Hydrofluoric Acid Ammonium Bi-flouride Bromic Acid Muriatic Acid Sulfonic Acid Phosphoric Acid Hydrogen Cyanide Hydrochloric Acid Chlorinated Solvents Belanger, Inc., does not endorse or condone the use of chemicals that are potentially dangerous to human health, the environment or property. Belanger recognizes that it is the right and sole decision of the end user operators of our equipment as to the type and dilution ratio of the chemicals used in their facilities. We strongly recommend that the end user does not select products containing any of the chemicals listed above as an ingredient in the wash solutions. The chemicals listed above are potentially dangerous to human health, and have a detrimental, deteriorating effect on the equipment and the facility. Be advised that a portion of, or all of your warranty will be voided if you determine to use any of the chemicals listed above as an ingredient in the wash solutions in conjunction with your Belanger automatic car wash equipment: Limitation (4), of Paragraph (8), Limited Warranty, of the Belanger Terms and Conditions of Sales describes the potential limitation of warranty due to your chemical selection: (4) This warranty shall be void for all equipment failures and premature component wear caused by the use of corrosive chemicals in the wash process. The following list includes some, but not all, of the particularly corrosive chemicals that if used in conjunction with Belanger equipment will void the warranty: Hydrofluoric Acid, Ammonium Bi-flouride, Bromic Acid, Muriatic Acid, Sulfonic Acid, Phosphoric Acid, Hydrogen Cyanide, Hydrochloric Acid, and Chlorinated Solvents. The Purchaser also agrees to accept the responsibility and liability for the selection and use of any chemicals listed above; However, should the end user decide to use formulations containing any of the above ingredients, the end user should institute a comprehensive training program and implement detailed operational parameters within their organization for the proper handling and treatment of such products to minimize the potential dangers involved. Consult your chemical supplier for assistance in establishing operational guidelines in the use of their products. MSDS (Material Safety Data Sheet) should be obtained from the chemical supplier before using any chemical formulation. CAUTION During the installation process the installer is responsible for re-tightening ALL lugs, set screws and terminals located in the electrical panels. Components may vibrate loose during shipping. 2 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL-KT113

Important Safety Information This section introduces the hazard and safety precautions associated with installing, maintaining or servicing this product. Before performing any task on this product, read this safety information and the applicable sections in this manual, where additional hazards and safety precautions for your task may be found. Electrical shock could occur and cause death or serious injury if these safe service procedures are not followed. Safety Symbols and Signal Words Alert Symbol This safety alert symbol is used in this manual and on warning labels to alert you to precautions which must be followed to prevent potential personal safety hazards. Obey safety directives that follow this symbol to avoid possible injury or death. Signal Words The signal words used in this manual and on warning labels tell you the seriousness of particular safety hazards. The precautions that follow must be followed to prevent death, injury or damage to the equipment. DANGER This signal word is used to alert you to a hazard or unsafe practice which WILL RESULT IN DEATH OR SERIOUS INJURY This alerts you to a hazard or unsafe practice which COULD RESULT IN DEATH OR SERIOUS INJURY CAUTION This signal word designates a hazard or unsafe practice which MAY RESULT IN MINOR INJURY CAUTION When used by it self, CAUTION designates a hazard or unsafe practice which MAY RESULT IN PROPERTY OR EQUIPMENT DAMAGE Before You Begin Only trained or authorized individuals knowledgeable in the related procedures should install, inspect, maintain or service this equipment. Read the Manual Read, understand and follow this manual and any other labels or related materials supplied with this equipment. If you do not understand the procedure, call a Belanger, Inc. representative at 248-349-7010. It is imperative to your safety and the safety of others to understand the procedures before beginning work. 1MANUL-KT113 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 3

Introduction Overview This kit is to be used on machines S/N 103 or larger to eliminate the treadle on Vectors so equipped. Belanger has shipped 3 versions of the Vector since its inception. To check your version, go to the E-300 setup screen. Look at the main software version in the upper right hand corner. The first number is the version. Example would be (main 03.35) would be a REV 3 machine and (main 02.21) would be a REV 2 machine. This upgrade cannot be done on a rev 1 machine. A REV 2 machine must first be modified to a REV 3 configuration. Call technical support for a list of upgrade requirements you have a REV 2 machine. Parts Included This kit should include the following parts. Retro Fit Kit Part Number Description Qty. Remarks 6753 Treadlefree Encoder Rail Spacer 2 new picket fence spacers 6752 Treadlefree Encoder Home Plate 1 New Shuttle home target 1ELECT-FS462 Micro Splitter 1M 90 deg 2 Y cables to allow for 2 new inputs 1ELECT-FS458 Micro Cable end connector 1 Used for D/S sonar cable 1ELECT-SN945 Side Sonar 1 Driver side sonar 1ELECT-CB882 Single end cable 1 Cable for side sonar 1ELECT-SN368 12 MM prox for shuttle home 1 Shuttle home prox 6525 Side Sonar mount plate 1 6524 Side sonar clamp 1 1FSTNR-SH343 Bolts sonar to bracket 4 sonar to plate 1FSTNR-SH177 Bolts bracket to clamp 2 Plate to Clamp Site Specific Wall or Floor Mount Photo-eye set 2 Site Specific P/S upper manifold cover blue or red 2 1MANUL-KT113 VPS upgrade manual 1 109003 Call for Program updates to MCC 1TOOL125 1/8 drill bits 1 1TOOL130 15/32 drill bits 1 1MANUL585 Photo Eye Manual 1 Covers all Photo Eyes 6032 Encoder Rail Spacer 1 1FSTNR-HH420 3/8-16 x 5-1/2 bolt 3 1WASHR-FL498 Stainless steel flat washer 6 1WASHR-LC291 3/8 lock washer 3 1NUT-LC215 3/8 lock nut 3 6031 Vector Encoder Sensor 1 This update is only possible with systems that utilize Passenger Side Sonar. If system was previously configured with REV 2 software, be aware of the following: Move the Low Water input from x3 to x24. 030 is no longer Extra Source after download. Typically this light is connected to Y20 after this update has been performed. Y20 is Triple Foam. 4 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL-KT113

Installation Photo Eye Placement 1) Remove the existing Floor Treadle. 2) Mount the Load Photo Eyes as shown below, on the following page and per supplied diagram(s). 15 ( from inside edge of the Headbeam to the center of the Photo Eye Receiver) 9 ( from inside edge of the Headbeam to the center of the Photo Eye Emitter) 9 ( from inside edge of the Headbeam to the center of the Photo Eye Receiver) 15 (from inside edge of the Headbeam to the center of the Photo Eye Emitter) Centerline of Doorway and Headbeam Direction of Travel NOTE: In locations where freezing can occur, you will need to install a method of heating the Photo-Eyes to keep them from freezing. The Photo Eye heights are covered on the next page. 1MANUL-KT113 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 5

Installation Photo Eye Placement 3) Run conduit and wires to Photo Eyes. Note that the Photo Eyes utilize same DC power and Inputs that the Treadle Proximity Switches were using. Wall Mounted, Overhead View 33 Receiver If Wall Mounted configuration is used, mount the Photo Eyes at the heights indicated Once mounted, the Photo Eyes are to be pivoted to point directly at each other End View Emitter 16 Receiver Mount the Photo Eyes with a minimum of 6 off-set Once mounted the Photo Eyes are to be angled to point directly at each other Overhead View Emitter 6 6 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL-KT113

Installation Shuttle Home Target 6032 (4-3/8 long) 6753 (4 long) 6951 6752: Homing Plate 6031: Picket Fence (with off-set holes) 1) Remove both belly pans from the bottom of the Vector carriage and set aside. Jog the shuttle as far as it will go toward the driver side of the bay and press the E-Stop. 2) Disconnect the cable from the current shuttle position proximity switch and remove the proximity switch from the Vector while being careful not to damage the proximity switch. 3) There are 3 bolts that hold the picket fence onto the shuttle rail. Remove the bolt closest to the passenger side wall. Now jog the shuttle as far as it will go toward the passenger side wall and disconnect the power and follow proper lock out procedures. 4) Remove the two remaining picket fence bolts and remove the center spacer and one closest to the driver side wall from inside the shuttle rail. Replace these 2 spacers with P/N 6753. They look the same but are 3/8 shorter. 5) Install the shuttle Home Plate P/N 6752 and the picket fence as shown below. NOTE: THE PICKET FENCE HAS 3 SLOTS FOR THE BOLTS. ONE END HAS THE SLOT 2 CLOSER TO THE END THAN THE OTHER SIDE. THE SLOT CLOSEST TO THE END SHOULD BE ON THE DRIVER SIDE OF THE CARRIAGE WITH THE HOME PLATE. 6) Reinstall 2 bolts and tighten with the Home Plate edge lined up with the center of the middle tab (15 th ) on the picket fence. Make sure both the fence and Home Target are slid all the way to the driver side and then tighten the 3 bolts. 7) Secure part number 6951 (shown below) to the end of the bolt. 8) Power up the machine but do not RESET or HOME the machine. Jog the shuttle toward the driver side and replace the third bolt in the picket fence. 9) Disconnect the power and follow proper lock out procedures. 6031 6032 6752 6753 6951 Homing Components Exploded 1MANUL-KT113 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 7

Installation Shuttle Home Proximity Switch 1) Mark and center-punch 1 above the current shuttle proximity switch holes as shown below. NOTE: NOTE PROXIMITY SWITCH WAS REMOVED EARLIER IN THIS PROCEDURE. 2) Drill a pilot hole about 1/8 diameter and then open up to 15/32 diameter with drill supplied. Power up the machine but do not reset or home the machine. Existing hole New 15/32 hole 1 higher for second Proximity Switch 3) Jog the shuttle toward the driver side until the proximity switch holes are in front of both the picket fence and the home plate and reinstall the lower proximity switch in the threaded hole and lock with the jam nut. The proximity switch should be 1/16 to 1/8 from the picket fence. 4) Install the upper proximity switch in the new hole. A jam nut is required on both sides. This proximity switch will stick out 3/8 farther than the lower one. 5) Adjust it so the proximity switch is 1/16-1/8 from the new shuttle home plate and reconnect the wire to the lower proximity switch. Bottom out the proximity switch and back it out 1-1/2 turns. 1/16 1/8 Proximity Switches Installed 1/16 1/8 Proximity Switches Installed (Side View) 8 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL-KT113

Installation Width Sonar 1) Remove the plastic cover from the driver side upper manifold and install driver side width sonar just like the one on the passenger side. 2) Connect a wire with dielectric grease to the sonar, and run it through the upper manifold then through the butterfly bearing and cord grip. Make sure spiral wrap from manifold to bearing, covers and protects all wires from chafing. Leave this for now. You will cut off the end and wire the connector later in this document. 3) Install a new cover with sonar clearance, on the upper manifold and tie wrap the top through the holes. Install 2 nd Width Proximity Sensor View from the Entrance 1MANUL-KT113 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 9

Installation Utility Connections 1) Remove the passenger side Breakaway from Port 1 of the junction block. 2) Remove the driver side Breakaway from Port 5 of the junction block. 3) Install 2 supplied Micro Splitter Y-Cables. 4) Install the Breakaways to the cable coming from the right side of the Y-Cable on the same port that they were removed from. 5) Connect the cable coming from the left side of the Y-Cable of Port 1 to the newly installed Shuttle Home port and reconnect the existing Shuttle Proximity Switch cable to the Shuttle Proximity Switch. 6) Wire the supplied connector onto the cable coming from driver side Sonar Unit per diagram. Once completed, connect it to the left side of the Y-Cable from Port 5. 7) Connect the new Input wires to Input terminals in the MCC. Gray/Pink X36 White/Yellow X25 Colored wires are from yellow cable of Micro Junction Block located in the Carriage Assembly as shown below. 10 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL-KT113

Installation Software Note: Kit is supplied with an E-Prom Chip. This E-Prom must be inserted in the face of the PLC for updating software. Be aware that if a future download is required via modem, the chip must be removed first. 1) Confirm that the power is off 2) Remove the cover from the face of the PLC. 3) Press the chip over the matching connector. 4) Place the cover back onto the PLC. Initial Startup Before You Begin Use INPUT lights on the PLC to check operation of both Breakaways, Shuttle Home Proximity Sensor, Shuttle Position Proximity Sensor and the Driver Side Sonar before operating machine. NOTE: IF SOFTWATE HAS BEEN UPDATED TO THE VIRTUAL POSITIONING SYSTEM VERSION, RUN A TEST VEHICLE. Understanding the Virtual Positioning System The sensors used for vehicle navigation respond differently in four separate phases of the wash cycle. Phase 1. Initial Position of Vehicle Within the Bay Phase 2. Locate the Front and Sides of the Vehicle Phase 3. Initial Butterfly Inward Motion at the Front of the Vehicle to Start the Wash Cycle Phase 4. Normal Wash Cycle in Progress 1MANUL-KT113 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 11

Initial Startup Understanding the Virtual Positioning System Phase 1: Initial Position of Vehicle within the Bay To initiate a normal wash, the vehicle must be between the Bay Limit Photo Eyes (Entrance and Exit Load Sonar Units) and under the machine. The actual position that the vehicle stops at is not critical as long as it meets the two described conditions shown below. The vehicle will be instructed to pull forward until it enters the Entrance Photo Eyes and completely passes through them. The vehicle also must be under both Sonar units. 1) A vehicle is considered under the machine when it blocks both Carriage mounted Sonar Units from sensing the floor. 2) A vehicle is considered between the Limit Photo Eyes when the beams from both sets of Photo Eyes are NOT blocked by the vehicle. Initial position before machine motion begins. Vehicle shown at approximate entrance most acceptable position. The STOP light comes on when the vehicle is in this position. Vehicle shown at approximate exit most acceptable position. Light Control STOP Both Photo Eyes made and both Sonar Units blocked. FORWARD The Enter Load Photo Eyes are blocked. BACKWARD The Exit Load Photo Eyes are blocked. 12 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL-KT113

Initial Startup Understanding the Virtual Positioning System Phase 2: Locate the Front and Sides of the Vehicle When motion initially starts, the vehicle must not block the Exit Limit Photo Eyes beam nor clear Entrance Sonar. The Exit Sonar is removed from position control when sizing front and sides of vehicle. If the Exit Limit Photo Eyes beam is broken, the vehicle will be instructed to back up. If the Entrance Sonar is cleared, the vehicle will be instructed to pull forward. During initial positioning, system locates front of vehicle and then sizes the width. Carriage is shown at HOME position. Carriage shown at position where front end of vehicle has been located. Light Control STOP Exit Load Photo Eyes made and Entrance Sonar Unit blocked. FORWARD The Enter Sonar is made (NOT BLOCKED). BACKWARD The Exit Load Photo Eyes are blocked. 1MANUL-KT113 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 13

Initial Startup Understanding the Virtual Positioning System Phase 3: Initial Butterfly Inward Motion at the Front of the Vehicle to Start the Wash Cycle The Exit Sonar must be made before the first front butterfly inward motion can take place. The first butterfly inward motion takes place immediately after the width sizing is complete. The vehicle will be instructed to back up until the sonar is made. The sonar is considered made when it senses the floor. After the width has been sized, machine must butterfly in front to start cycle. Light Control Image shows Exit Sonar in position to sense the floor. STOP Exit Sonar made (NOT BLOCKED). BACKWARD The Sonar Units are blocked. 14 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL-KT113

Initial Startup Understanding the Virtual Positioning System Phase 4: Normal Wash Cycle in Process The vehicles forward and backward position may change during cycle. The machine will continue to wash the vehicle even if it moves, provided it does not break the Exit Limit Photo Eye beam nor allow both Sonar Units to be made while machine is passing HOME position. After the initial butterfly in front on the vehicle, the machine is in its Normal Wash Cycle. Vehicle is shown in original position when wash started. Vehicle shown in position that it rolled to during cycle. Light Control BACKWARD wash is behind the HOME position and the Exit Photo Eyes have been broken for one second the vehicle will be instructed to back up and the machine will stop. The vehicle will be asked to back up until the Exit Sonar has been broken for.8 seconds and the Exit Photo Eyes are made. FORWARD If both sonar units see the floor while the machine passes the HOME position the vehicle will be instructed to pull forward and the machine will stop. The vehicle will be asked to pull forward until the Entrance Sonar has been broken for.8 seconds and the Entrance Photo Eyes are made. STOP Latched on until backward or forward condition sensed. 1MANUL-KT113 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 15

Initial Startup Understanding the Virtual Positioning System Phase 1: Limousine Exception If vehicle is long enough to block both sets of Photo Eyes simultaneously, it will be instructed to back up until the Exit Photo Eyes have been made. The machine will wash these vehicles but never butterfly in on the rear of the vehicle. Initial position before machine motion begins. Image shows limousine blocking both sets of Photo Eyes. The limousine will be asked to back up until the above position is approximately reached. 16 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL-KT113

Virtual Positioning System Retrofit Kit 1MANUL-KT113 Belanger, Inc. * P.O. Box 5470 * Northville, MI 48167 Customer Service Phone (248) 347-4700 * Fax (248) 380-9681