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Scully Intellicheck 3R Series Technical Manual

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Technical Manual
for
Over ll / Retained
Over ll Prevention & Retained Product
Detection for up to 8 Compartments
Monitoring System for Tank Truck Loading
Featuring Dynamic
Self-Checking
®
www.scully.com

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Summary of Contents for Scully Intellicheck 3R Series

  • Page 1 Technical Manual Over ll / Retained Over ll Prevention & Retained Product Detection for up to 8 Compartments Monitoring System for Tank Truck Loading Featuring Dynamic Self-Checking ® www.scully.com...
  • Page 2 Intellicheck 3R Over ll/Retained Technical Manual ® Table of Contents 1. General Information Technical Speci cations Approvals Intrinsic Safety Entity Parameters Standards Compliance Label 2. Mechanical Installation IntelliCheck 3R and Socket Installation ® Over ll Sensors Mounting Retained Sensors Mounting 3.

  • Page 3: Table Of Contents

    Over ll Prevention & Retained Product Detection Table of Contents 6. Socket & Switch Wiring Five-Wire Optic Connection Two-Wire Optic (Thermistor) Connection Reset Switch (Retain Acknowledge Override Button) Auxiliary Switch Input Non Intrinsically Safe (Non I.S.) Relay Output Intrinsically Safe ( I.S.) Relay Output 7.

  • Page 4: General Information

    • Bicolor LEDs providing complete system diagnostics, includes sensors, power, and rack connection. • Corrosion-resistant housing. • Scratch-resistant window. • Overfill connections are Compatible with Scully’s SP-TO Two-Wire and SP-FU Five Wire Optic Sensors. • Retain connections are compatible with Scully's SP-TO Two-Wire Optic sensors.
  • 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 3R monitor and sensors are being ®...
  • Page 6 Intellicheck 3R Over ll/Retained Technical Manual ® General Information Retained Product Monitoring Product retention warning and prevention alerts the operator of existing product in a compartment. This feature prevents miscalculation of loading volumes leading to over lls. If existing product is on board the vehicle prior to loading, the retained feature is con gured to “lock-out”...
  • Page 7 Over ll Prevention & Retained Product Detection 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 3R Over ll/Retained Technical Manual ® General Information • Europe: IECEx ETL 15.0004 ITS15ATEX58179 1180 2575 ITS22UKEX0559 Ex eb mb [ia Ga] IIB T4 Gb -40°C < Ta < +60°C WARNING: Exposure to some chemicals may degrade the sealing properties of materials used in the sealed module device.
  • Page 9 • 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 ® 3R module. • Wiring to and from the Intellicheck 3R must conform to wiring ®...
  • Page 10 Intellicheck 3R Over ll/Retained Technical Manual ® General Information 1.4 Standards U.S.A. • Intrinsically Safe Apparatus and Associated Apparatus for Use in Class I, II, and III, Division 1, Hazardous (Classi ed) Locations [UL 913:2013 Ed.8+R:16Oct2015] • Nonincendive Electrical Equipment for Use in Class I and II, Division 2 and Class III, Divisions 1 and 2 Hazardous (Classi ed) Locations [UL 121201:2017 Ed.9 +R:01Apr2021] •...
  • Page 11 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 12: Mechanical Installation

    Intellicheck 3R Over ll/Retained Technical Manual ® Mechanical Installation Locating and mounting the IntelliCheck 3R monitor, sockets and over ll ® sensors. Pre-Installation Requirements When choosing a location to install the IntelliCheck ® 3R System, these guidelines must be followed: •...
  • Page 13 Over ll Prevention & Retained Product Detection Mechanical Installation • The IntelliCheck 3R can be installed inside a tool cabinet on ® the side of the truck. • The IntelliCheck 3R 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 14 Intellicheck 3R Over ll/Retained Technical Manual ® 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 15: Electrical Installation

    Over ll Prevention & Retained Product Detection Electrical Installation Note: We strongly suggest the use of a Scully IntelliCheck 3R wiring installation ® kit. Wire installation kits include conductor cable, cable compression ttings, on/off switch, and crimp-on connectors. Depending on the number of vehicle compartments and sensor type, the conductor cable included in the installation kit will be either 100’...
  • Page 16 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 17 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 18 • Connect power to the module. We recommend the use of (18-AWG) gauge wire or the Scully cable using only the red and black wires. (The Scully cable in 5, 7, and 11 conductors, all use the same cable gland.) •...
  • Page 19 Over ll Prevention & Retained Product Detection Electrical Installation 12/24 V 0.5A • On the IntelliCheck 3R, 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 Below Screw 0.5A...
  • Page 20 Intellicheck 3R Over ll/Retained Technical Manual ® 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 each sensor holder compartment, except compartment number 1.
  • Page 21 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 3R monitor.
  • Page 22 Intellicheck 3R Over ll/Retained Technical Manual ® Electrical Installation Cable Sealing Diagram Sensor Holder Cup Cable Compression Fitting (Strain Relief) Apply Silicone Here Push Cable into Fitting .5” to Form a Seal Here Over ll Sensor Cable Compression Fitting (Strain Relief) Apply Silicone Here...
  • Page 23 Once the unit reaches the maximum program limit (7) it will be locked to that setting and can not be reprogrammed again. In order to reset it back to default it will need to be returned to Scully Signal Company.
  • Page 24 TB4-GND to TB4 Terminal 4. OVERFILL SENSORS 8 7 6 5 4 3 2 1 Example of programming for a 4 compartment Over ll / Retained vehicle using Scully’s Two-Wire Optic Sensors. 3. Apply power to the IntelliCheck ® Page 21.
  • Page 25 Over ll Prevention & Retained Product Detection On-Vehicle Programming 4. For this example, the indicator lights representing both Over ll / Retained con gured sensors (1,2 and 3) will be ashing synchronously, alternating between red and green, with the indicator light representing the highest con gured sensor (4) ashing at twice the rate of the other con gured sensors.
  • Page 26 RETAINED SENSORS 8 7 6 5 4 3 2 1 Example of programming for a 4 compartment vehicle using Scully's Two-Wire Optic Sensors in PARALLEL 3. Apply power to the IntelliCheck ® 4. For this example, The the retained indicator lights representing...
  • Page 27 OVERFILL SENSORS 8 7 6 5 4 3 2 1 Example of programming for a 4 compartment vehicle using Scully’s Five-Wire Optic Sensors wired in SERIES with Two-Wire Optic Retain sensors wired in PARALLEL 4. Apply power to the IntelliCheck ®...
  • Page 28 Intellicheck 3R Over ll/Retained Technical Manual ® On-Vehicle Programming Note: The fast ashing LED should match whatever sensor has the program jumper attached. 6. Leave the unit powered up for approximately 10 seconds. Then remove power from the IntelliCheck 3R and remove the ®...

  • Page 29: Sensor Wiring

    Over ll Prevention & Retained Product Detection Sensor Wiring • Feed the cable through the bottom left-hand corner compression tting (Port D & F) to allow approximately 12.5 cm (5 inches) of cable into the IntelliCheck 3R housing. ® PORT D PORT F •...
  • Page 30 Intellicheck 3R Over ll/Retained Technical Manual ® Sensor Wiring 5.1 Two-Wire Over ll and Retain Sensor Wiring 1. Connect all con gured sensors to TB4 and TB5 per drawing below (Full con guration of 8 compartments is shown for reference). 2.
  • Page 31 Over ll Prevention & Retained Product Detection Sensor Wiring 5.2 Two-Wire Retain Only Sensor Wiring 1. Connect all con gured sensors to TB5 per drawing below (Full con guration of 8 compartments is shown for reference). 2. Turn on Power. 3.
  • Page 32 Intellicheck 3R Over ll/Retained Technical Manual ® Sensor Wiring 5.3 Five-Wire Series Over ll / Two-Wire Parallel Retained Sensor Wiring 1. Connect all con gured sensors to TB4 and TB5 per drawing below (Full con guration of 8 compartments is shown for reference).

  • Page 33: Socket & Switch Wiring

    ® • Install compression fitting in Port H. PORT • Feed the Scully cable through a compression fitting for each socket into Port H. Leave about 3 inches of extra cable inside the IntelliCheck 3R housing for connection and future ®...
  • Page 34 Intellicheck 3R Over ll/Retained Technical Manual ® Socket & Switch Wiring 6.1 Five-Wire Optic Connection Rear View SJ-6SO or SJ-6W (A)RED (B)ORN Pin 9 for both sockets is for Ground Bolt if so equipped • Connect the cable wires by their appropriate color to the corresponding pin numbers of the socket according to the socket style and type, Five-Wire Optic or Two-Wire Optic (Thermistor).
  • Page 35 Over ll Prevention & Retained Product Detection Socket & Switch Wiring 6.2 Two Wire Optic (Thermistor) Connection Rear View SJ-8S (A)RED (B)ORN Pin 9 for both sockets is for Ground Bolt if so equipped • Loosen the pin set screw. Slip the exposed wire into the pin and tighten the set screw.
  • Page 36 Intellicheck 3R Over ll/Retained Technical Manual ® Socket & Switch Wiring 6.3 Reset Switch (Retain Acknowledge Override Button) For retained operations, a reset switch is connected via Port C to TB3 pins 3 & 4. This is used to AUX 1 acknowledge and override any compartment retain indicator.
  • Page 37 Over ll Prevention & Retained Product Detection 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 I.S. (non-I.S.wiring). CONTROL The IntelliCheck ® 3R provides a relay contact output on TB6 that can be used to drive a Intrinsically Safe load.

  • Page 38: Cover Tightening

    Intellicheck 3R Over ll/Retained 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. Torque Sequence Place the gasket, window and cover onto the enclosure housing and lightly tighten all twelve stainless steel hex bolts with lock washer.

  • Page 39: Operations

    Over ll Prevention & Retained Product Detection 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 40 Intellicheck 3R Over ll/Retained Technical Manual ® Operations The OVERFILL / RETAINED SENSOR indicator light conditions are as follows: (programmed for 6 compartments) • Green Light On - Sensor is operating normally. (In this state, the GREEN permit indicator is on and the DYNACHECK indicator ®...
  • Page 41 Over ll Prevention & Retained Product Detection 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 indicator is ashing.) ®...

  • Page 42: Intellicheck

    Intellicheck 3R Over ll/Retained Technical Manual ® Operations The IntelliCheck 3R controller has diagnostic indicators that report on ® several aspects of system operation. These diagnostics are: • DYNACHECK - When this GREEN indicator is pulsing, the ® IntelliCheck 3R module is functioning. The pulsed indication signi es ®...

  • Page 43: Technical Service

    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 44 Intellicheck 3R Over ll/Retained Technical Manual ® Control Drawing 61667 Rev E Page 41.

  • Page 45: Appendix

    Over ll Prevention & Retained Product Detection Appendix Recommended Scully Sockets (A)RED (B)ORN Rear View SJ-6SO or SJ-6W Rear View SJ-8S Pin 9 for both sockets is for Ground Bolt if so equipped Alternate Single Sockets (A)RED (B)ORN Rear View SJ-6SO or SJ-6W...
  • Page 46 Rear View API (WOGA) Style Optic ATA Style 4-Pole Socket Rear View API Style Themistor Socket Alternate ‘SAE J560” Single Sockets (A)RED (B)ORN Rear View SJ-6X Rear View SJ-6 (Scully 7 Pole Socket) (Scully 7 Pole Socket) 5-Wire 2-Wire Page 43.

  • Page 47: Parts List

    Over ll Prevention & Retained Product Detection Parts List COMPLETE ASSEMBLY Part Number Description 09566 Intellicheck 3 Over ll / Retained Monitor ® UPGRADE KIT Part Number Description 09585 Intellicheck 3-R Upgrade Kit, Over ll / Retained ® REPLACEMENT PARTS 5 &...
  • Page 48 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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