Scully Intellicheck 3 NPT Technical Manual

5 compartment multi-level overfill prevention monitoring system for tank truck loading

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Technical Manual

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Multi-Level

5 Compartment Multi-Level Over ll Prevention

Monitoring System for Tank Truck Loading

Featuring Dynamic

Self-Checking

www.scully.com

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Page 1 Technical Manual Multi-Level 5 Compartment Multi-Level Over ll Prevention Monitoring System for Tank Truck Loading Featuring Dynamic Self-Checking ® www.scully.com...
Page 2: Table Of Contents
Intellicheck 3 Multi-Level Technical Manual ® Table of Contents 1. General Information Technical Speci cations Approvals Intrinsic Safety Entity Parameters Standards Compliance Label 2. Mechanical Installation IntelliCheck 3 and Socket Installation ® Over ll Sensors Mounting 3. Electrical Installation IntelliCheck 3 Power Wiring ®...
Page 3 Multi-Level Over ll Prevention Monitoring System Table of Contents 7. Cover Tightening 8. Operations Sensor Diagnostics Intellicheck 3 System Diagnostics ® Technical Service 9. Control Drawing 10. Appendix 11. Parts List...
Page 4: General Information
• Corrosion-resistant housing • Scratch-resistant window • Compatible with Scully’s SP-TO Two-Wire Optic Sensors • Intrinsically safe and non-intrinsically safe switch outputs. The IntelliCheck 3 Multi-Level is suitable for use on vehicles up to ve ®...
Page 5 ® requiring secondary over ll prevention. Faylsafe operation is ® incorporated into the Scully design technology by utilizing Dynacheck ® Scully’s unique automatic and continuous self-checking feature. This feature ensures the IntelliCheck 3 monitor and sensors are being contin- ®...
Page 6 Intellicheck 3 Multi-Level Technical Manual ® General Information The lower level, referred to as High, when wet will signal a non-permit via output to the standard API optical and thermistor sockets AND open the non-I.S. switch on TB1. The I.S. switch associated with the compartment being lled will not be affected by a wet High sensor.
Page 7: Approvals
Multi-Level Over ll Prevention Monitoring System General Information 1.1 Technical Speci cations Temperature Range Operating: -40 to +60 Degrees C (-40 to +140 Degrees F) Storage: -45 to +85 Degrees C (-50 to +185 Degrees F) Power Requirement: Nominal Voltage: 12 to 24 VDC (-0.5, +8 VDC) Consumption: 9.6 Watts maximum at 24 VDC...
Page 8 Intellicheck 3 Multi-Level Technical Manual ® General Information 1.2 Approvals IntelliCheck ® 3 has safety approvals as an intrinsically safe monitoring device for use in: • Canada and the United States: Class I, Division 2, Group CD, T6, Type 4 or Class I, Zone 2, IIB T6, IP 65 With intrinsically safe outputs for Class I, Division 1, Group CD...
Page 9 Multi-Level Over ll Prevention Monitoring System General Information AVERTISSEMENT: L'exposition à certains produits chimiques peut dégrader les propriétés d'étanchéité des matériaux utilisés dans les module étanche périphérique. AVERTISSEMENT: Risque d’explosion – ne pas debrancher tant que le circuit est sous tension, a moins qu’il ne s’agisse d’un emplac ment non dangereux.
Page 10 • Do not allow the unit to come in contact with aggressive substances. • Do not allow build-up of dust on the monitor. • Electrical repair is limited to replacing the internal module with an equivalent Scully IntelliCheck 3 module. ®...
Page 11: Standards
Multi-Level Over ll Prevention Monitoring System General Information 1.4 Standards United States and Canada • UL 913, Ed:8 Rev:2015 UL Standard for Safety: -Intrinsically Safe Apparatus and Associated Apparatus for Use in Class I, II and III, Division 1, Hazardous Locations •...
Page 12: Compliance Label
CERTIFIED TO STANDARDS: to Class I, Division 1, Group CD. Class I; Zone 0, IIB hazardous ETL14CA101487821 locations, in accordance with Scully Control drawing 61667. CSA C22.2#61010-1-12, 61010-2-201, Input 12-24 Vdc, 6 W, Um = 32 Vdc, -40°C ≤ Ta ≤ 60°C...
Page 13: Mechanical Installation
Multi-Level Over ll Prevention Monitoring System Mechanical Installation Locating and mounting the IntelliCheck 3 monitor, sockets and over ll ® sensors. Pre-Installation Requirements When choosing a location to install the IntelliCheck ® 3 System, these guidelines must be followed: • Appropriate industry, national, state and local codes. •...
Page 14: Intellicheck
Intellicheck 3 Multi-Level Technical Manual ® Mechanical Installation • The IntelliCheck ® 3 can be installed inside a tool cabinet on the side of the truck. • The IntelliCheck 3 does not necessarily have to be located ® beside the socket housings, but mounted in an area that is visible to the operator as well as accessible to service personnel.
Page 15 Multi-Level Over ll Prevention Monitoring System Mechanical Installation 9.26 (235.2) 8.50 (9.6) (215.9) 6.81 (173) 5.00 Ø.31 (127) 4 holes 2.54 Conduit / Cable entry holes: 1/2” NPT 2.2 Over ll Sensors Mounting The SP-TO sensors should be mounted in each compartment to permit accessible, in-place testing after the initial installation is complete.
Page 16: Electrical Installation
Intellicheck 3 Multi-Level Technical Manual ® Electrical Installation Note: We strongly suggest the use of a Scully IntelliCheck 3 wiring installation ® kit. Wire installation kits include conductor cable, cable compression ttings, on/off switch, and crimp-on connectors. Refer to the Appendix for detailed electrical connections. The diagrams...
Page 17 Wire splices should be made in external watertight junction boxes. Water Proo ng: To avoid future maintenance issues regarding water in ltration into the housing via the electrical cable/conduit entries, Scully strongly recommends the following precautions: 1. Long vertical cable/conduit runs into the sides of the enclosure should be minimized as they promote water channeling to the cable/conduit gland/seal tting packing.
Page 18 IntelliChecks . The cause of this is poor or insuf cient sealing of conduit ® openings. Scully provides wire cable and gland/seals parts and kits, which are matched to assure a seal. A. North American Installations To maintain NEMA 4 rating, all NPT threaded joints of Cable glands or conduit should be wrench tight.
Page 19 Give a slight tug to the wire to ensure a good connection. • Connect power to the module. We recommend the use of 1mm2 (18-AWG) gauge wire or the Scully cable using only the red and black wires. (The Scully cable in 5, 7, and 11conductors, all use the same cable gland.)
Page 20 Intellicheck 3 Multi-Level Technical Manual ® Electrical Installation • Insert the exposed red wire into the TB1-1 12/24V contact #1 and tighten. • On the IntelliCheck 3 check that the Green with yellow stripe ® wire’s ring terminal from TB1-3 is placed under the potted module’s mounting screw Ground Ring Terminal Power Supply...
Page 21 Multi-Level Over ll Prevention Monitoring System Electrical Installation 3.2 Truck Sensor Wiring - General General wiring guidelines are presented here, for speci c instructions please refer to the installation manual shipped with the sensors. 1. Connect a compression tting to each conduit entrance hole on the high-high sensor holder.
Page 22 This will also prevent condensation from seeping through. At the last compartment sensor, feed a length of the Scully cable down the back of the vehicle. Be sure to neatly anchor the cable as you go to the IntelliCheck 3 monitor.
Page 23: On Vehicle Programming
Example of programming for a HIGH-HIGH SENSOR 4 compartment vehicle using 8 7 6 5 4 3 2 1 Scully’s 2-Wire Optic Sensors. 3. Apply power to the IntelliCheck ® 4. For this example, The indicator lights representing con gured sensors...
Page 24: Sensor Wiring
Intellicheck 3 Multi-Level Technical Manual ® Sensor Wiring • Feed the cable through the bottom left-hand corner compression tting (Port D) to allow approximately 12.5 cm (5 inches) of cable into the IntelliCheck 3 housing. ® PORT D PORT F •...
Page 25 Multi-Level Over ll Prevention Monitoring System Sensor Wiring 2-Wire Multi-Level Liquid Level Sensors HIGH-HIGH SENSOR HIGH SENSOR 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 HIGH-HIGH SENSOR HIGH SENSOR Page 22.
Page 26 • To make the connection, strip about a 6mm (1/4") off each cable lead. • Slip the exposed wire into the corresponding number pin of TB6 6.1 5-Wire (Optic) Connection RECOMMENDED SCULLY SOCKETS (A)RED or YEL RED/BLK (B)ORN or ORN/BLK...
Page 27 Multi-Level Over ll Prevention Monitoring System Socket & Switch Wiring 6.2 2-Wire Optic (Thermistor) Connection RECOMMENDED SCULLY SOCKETS (A)RED or YEL RED/BLK (B)ORN or ORN/BLK Rear View SJ-8S Pin 9 for both sockets is for Ground Bolt if so equipped Note: Refer to Appendix for additional wiring diagrams.
Page 28 Intellicheck 3 Multi-Level Technical Manual ® Socket & Switch Wiring 6.4 Auxiliary Switch Input, TB3 Do NOT under any circumstances mix Intrinsically Safe (I.S.) with non-Intrinsically Safe (non-I.S.wiring). There is an Intrinsically Safe (I.S.) auxiliary switch input AUX 1 available. A new factory unit includes a factory-installed jumper across the two terminals.
Page 29 Multi-Level Over ll Prevention Monitoring System Socket & Switch Wiring 6.6 Intrinsically Safe ( I.S.) Relay Output Do NOT under any circumstances mix Intrinsically Safe (I.S.) with non-Intrinsically Safe (non-I.S.wiring). The IntelliCheck 3 Multi-level provides eight FET ® switch outputs on TB6 that can be used to drive intrinsically safe loads.
Page 30: Cover Tightening
Intellicheck 3 Multi-Level Technical Manual ® Cover Tightening After all the connections to the module are made, apply a small amount of white lube or non-conductive grease to all of the connections at TB1, TB2, TB3, TB4, TB5, TB6 and TB7 (if used) to prevent corrosion. Place the gasket, window and cover onto the housing and tighten in sequence as shown.
Page 31: Operations
Multi-Level Over ll Prevention Monitoring System Operations 8.1 Sensor Diagnostics Each sensor has an indicator light for its status located horizontally across the top of the module, behind the clear window of the housing. A quick reference for sensor diagnosis is listed on the outside cover. (Not only does the indicator show the status of a sensor condition, wet or dry, it also gives the sensor connection fault status and sensor operation fault indication as well.) The diagnostic indicators allow the...
Page 32: Intellicheck
Intellicheck 3 Multi-Level Technical Manual ® Operations The DUAL-LEVEL SENSOR indicator light conditions are as follows: (pre-programmed for ONE compartment) • Green Light On -Sensor is operating normally. (In this state, the GREEN permit indicator is on and the DYNACHECK ®...
Page 33 Multi-Level Over ll Prevention Monitoring System Operations • Red Light Is Flashing Fast (as compared to the DYNACHECK ® Indicator) -The sensor return line is shorted to ground or another return signal line. (In this state, the permit indicator is RED and the DYNACHECK ®...
Page 34 Intellicheck 3 Multi-Level Technical Manual ® Operations The IntelliCheck3 controller has diagnostic indicators that report on several aspects of system operation. These diagnostics are: • PERMIT- When this indicator is GREEN the IntelliCheck 3 System is ® indicating a permissive state to the loading rack terminal equipment. When this indicator is RED loading of the truck is not permitted DYNACHECK - When this GREEN indicator is pulsing, the...
Page 35 8.3 Technical Service If for any reason a fault is not detected, but the vehicle still has problems loading, call Scully’s Technical Service Department in the United States and Canada, at 1-800-272-8559, 24 hours per day. Be sure to have the results of the tests you have conducted when you call for assistance.
Page 36: Control Drawing
Intellicheck 3 Multi-Level Technical Manual ® Control Drawing 61667 Rev E Page 33.
Page 37: Appendix
(A)RED or YEL RED/BLK (B)ORN or ORN/BLK Rear View SJ-6S ALTERNATE SAE J560 SINGLE SOCKETS (A)RED or YEL RED/BLK (B)ORN or ORN/BLK Rear View SJ-6X Rear View SJ-6 (Scully 7 Pole Socket) (Scully 7 Pole Socket) 5-Wire 2-Wire Page 34.
Page 38 Intellicheck 3 Multi-Level Technical Manual ® Appendix MULTI-CEPT SOCKETS (A)RED or YEL RED/BLK (B)ORN or ORN/BLK Rear View Rear View Rear View API (WOGA) Style API Style ATA Style Optic Socket Themistor Socket 4-Pole Socket (A)RED or YEL RED/BLK (B)ORN or ORN/BLK Rear View Doucept 3 Sockets ®...
Page 39: Parts List
Multi-Level Over ll Prevention Monitoring System Parts List COMPLETE ASSEMBLY Part Number Description 09540 Intellicheck 3 Multi-Level Monitor- NPT ® 09541 Intellicheck 3 Multi-Level Monitor- M20 ® 09540-BYP Intellicheck 3 Multi-Level Monitor with Bypass- NPT ® 09541-BYP Intellicheck 3 Multi-Level Monitor with Bypass- M20 ®...
Page 40 Scully is ISO certi ed and all of our products are made in the U.S.A. In addition, we back up our products with the best service in the industry. We have direct sales and service personnel in the U.S.A., The United Kingdom, and...

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Intellicheck 3 m20 09540 09541 09540-byp 09541-byp