SICK VICOTEC320 Series, VICOTEC322, VICOTEC321, VICOTEC325, VICOTEC323 Operating Instructions Manual

I

Title Page

VICOTEC320
Air Quality Tunnel Sensors
Measurement of NO, NO2, CO and visibility
MMMOPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS
MMM
Described Product
Product name: VICOTEC320 Variants: VICOTEC321
VICOTEC322 VICOTEC323 VICOTEC325
Document ID
Title: Operating Instructions VICOTEC320 Part No.: 8011703/XF49 Version: V3-1 Release: 2019-09
Manufacturer
SICK AG Erwin-Sick-Str. 1 · D-79183 Waldkirch · Germany Phone: +49 7641 469-0 Fax: +49 7641 469-1149 E-mail: info.pa@sick.de
Trademarks
IBM is a trademark of the International Business Machine Corporation. MS-DOS is a Microsoft Corporation trademark. Windows is a Microsoft Corporation trademark. Other product names used in this document may also be trademarks and are only used for identification purposes.
Original document
This document is an original document of SICK AG. SICK AG assumes no liability for the correctness of an unauthorized translation. If in doubt, contact SICK AG or your local representative.
Legal Information
Subject to change without notice.
© SICK AG. All rights reserved.
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Contents

Contents
CONTENTS
1 About this document................................................................................. 7
1.1 Function of this document..............................................................................7
1.2 Scope of application ....................................................................................... 7
1.3 Target groups .................................................................................................. 7
1.4 Further information ......................................................................................... 7
1.5 Symbols and document conventions .............................................................7
1.5.1 Warning symbols ............................................................................ 7
1.5.2 Information symbols ....................................................................... 8
1.5.3 Warning levels and signal words....................................................8
1.6 Data integrity ................................................................................................... 8
2 For your safety............................................................................................ 9
2.1 Basic safety information ................................................................................. 9
2.2 Intended use .................................................................................................10
2.3 Responsibility of user....................................................................................10
3 Product description .................................................................................11
3.1 Product identification ...................................................................................11
3.1.1 Type plate......................................................................................11
3.2 Product features ...........................................................................................12
3.3 Device variants..............................................................................................12
3.4 Special features ............................................................................................12
3.5 Layout and function ......................................................................................13
3.5.1 Functional principle ......................................................................13
4 Project planning....................................................................................... 14
4.1 Assembly project planning............................................................................14
4.1.1 Arrangement along the tunnel section ........................................14
4.1.2 Arrangement in cross-section profile ...........................................14
4.1.3 Arrangement with special prerequisites ......................................16
4.2 Electrical installation project planning.........................................................17
5 Installation ................................................................................................ 19
5.1 Tools required ...............................................................................................19
5.2 Material required ..........................................................................................19
5.3 Preparing the installation location ...............................................................19
5.4 Transport .......................................................................................................19
5.5 Scope of delivery ...........................................................................................19
5.6 Assembly .......................................................................................................20
5.6.1 Fitting the assembly consoles ......................................................20
5.6.2 Fitting the VICOTEC320 sensors ..................................................21
5.6.3 Fitting the connection unit ...........................................................23
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CONTENTS
5.7 Electrical installation .................................................................................... 24
5.7.1 Electrical protection ..................................................................... 24
5.7.2 Connecting the sensors to the connection unit .......................... 25
5.7.3 Connection unit cabling ............................................................... 26
6 Commissioning ........................................................................................ 32
6.1 Necessary technical knowledge for commissioning ................................... 32
6.2 Commissioning checklist.............................................................................. 32
6.2.1 Device data................................................................................... 32
6.2.2 Tunnel data................................................................................... 32
6.3 Alignment ...................................................................................................... 33
6.4 Spectral analysis........................................................................................... 35
6.5 Visibility and smoke detection ..................................................................... 35
6.6 Signal outputs............................................................................................... 36
6.7 Saving data ................................................................................................... 36
7 Operation .................................................................................................. 37
7.1 Operating the VICOTEC320 .......................................................................... 37
8 Using the VICOTEC320............................................................................ 38
8.1 Software SOPAS ET....................................................................................... 38
8.1.1 Functions (overview) .................................................................... 38
8.1.2 Installing the SOPAS ET software ................................................ 38
8.2 Using SOPAS ET ............................................................................................ 38
8.2.1 Creating a connection .................................................................. 38
8.2.2 Reading out the VICOTEC320 and operating manually .............. 44
8.2.2.1 Exporting messages ................................................. 47
8.2.3 Saving the current parameter set................................................ 48
9 Maintenance............................................................................................. 49
9.1 Cleaning ........................................................................................................ 49
9.1.1 Cleaning sensors .......................................................................... 49
9.1.2 Tunnel cleaning ............................................................................ 49
9.2 Maintenance work ........................................................................................ 50
9.2.1 Persons authorized to carry out maintenance............................ 50
9.2.2 Replacing the activated charcoal ................................................ 50
9.2.3 Replacing the drying agent cartridge .......................................... 51
9.2.4 Replacing the sender lamp and LED ........................................... 52
9.2.5 Replacing the CO sensor.............................................................. 56
9.2.6 Span Test...................................................................................... 57
9.2.6.1 Determination and setting of the span factors .......59
10 Troubleshooting .......................................................................................60
10.1 Error messages ............................................................................................. 60
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CONTENTS
11 Technical data ..........................................................................................61
11.1 Dimension drawings......................................................................................61
11.1.1 Sender/receiver unit ....................................................................61
11.1.2 Reflector........................................................................................62
11.1.3 Connection unit.............................................................................63
11.2 Technical data ...............................................................................................64
11.3 Part Nos. ........................................................................................................66
11.3.1 Device components ......................................................................66
11.3.2 Type code ......................................................................................67
11.3.3 Accessories ...................................................................................68
11.3.4 Expendable and wearing parts.....................................................68
12 Annex .........................................................................................................69
12.1 Conformities and approvals..........................................................................69
12.2 Mapping table SCU .......................................................................................69
12.2.1 Measured values on SCU .............................................................69
12.2.2 Operating State Table...................................................................69
12.2.3 Status ............................................................................................70
12.2.4 Status of measured values ..........................................................70
12.3 Modbus Mapping Table ................................................................................71
12.3.1 Overview........................................................................................71
12.3.2 Status ............................................................................................73
12.3.3 Failure ...........................................................................................73
12.3.4 Maintenance request ...................................................................74
12.4 Password .......................................................................................................75
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CONTENTS
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1About this document

1.1 Function of this document

These Operating Instructions describe:
Device components
Installation
Operation
Maintenance work required for reliable operation

1.2 Scope of application

These Operating Instructions are only applicable for the measuring device described in the product identification.
They are not applicable for other SICK measuring devices.
The standards referred to in these Operating Instructions are to be observed in the respec­tive valid version.

1.3 Target groups

ABOUT THIS DOCUMENT 1
This Manual is intended for persons installing, operating and maintaining the device.

1.4 Further information

Observe the supplied documents.
Additional instructions
The following documents are applicable in addition to these Operating Instructions:
SOPAS ET Software Manual

1.5 Symbols and document conventions

1.5.1 Warning symbols

Symbol Significance
Hazard (general)
Hazard by voltage
Hazard in potentially explosive atmospheres
Hazard through explosive substances/substance mixtures
Hazard by ultraviolet radiation (UV light)
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1 ABOUT THIS DOCUMENT

1.5.2 Information symbols

Symbol Significance
Important technical information for this product
Important information on electric or electronic functions

1.5.3 Warning levels and signal words

DANGER:
Risk or hazardous situation which will result in severe personal injury or death.
WARNING :
Risk or hazardous situation which could result in severe personal injury or death.
CAUTION:
Risk or hazardous situation which could result in less severe or minor injuries.
NOTICE:
Hazard which could result in property damage.
Note:
Hints

1.6 Data integrity

SICK AG uses standardized data interfaces such as standard IP technology, in its products. The focus here is on the availability of the products and their properties.
SICK AG always assumes that the customer is responsible for the integrity and confidential­ity of data and rights involved in connection with using the products.
In all cases, the customer is responsible for the implementation of safety measures suit­able for the respective situation, e.g., network separation, firewalls, virus protection and patch management.
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2For your safety

2.1 Basic safety information

Read and always observe the safety and warning information in these Operating Instruc­tions.
WARNING: Hazards thro ugh defe ctive devic e
The VICOTEC320 is likely to be unsafe when it:
Shows visible damage on the outside.
Has been penetrated by moisture.
Has been stored or operated under irregular conditions.
When safe operation is no longer possible:
Put the VICOTEC320 out of operation, separate all connectors from the
power supply and secure against unauthorized commissioning.
WARNING: Risk of explosions through explosive sample gas
Do not use the VICOTEC320 to measure explosive, combustible or
flammable gases.
FOR YOUR SAFETY 2
WARNING: Explosion hazard in potentially explosive atmospheres
Do not use the VICOTEC320 in potentially explosive atmospheres.
CAUTION: Eye injuries caused by improper handling of UV or blue light beams The UV beam of the deuterium lamp or the blue light beam of the LED can cause serious injuries through direct eye and skin contact. This results in the following safety measures when working on the switched on device with access to the light beam exit:
Always wear UV protective goggles (in accordance with standard EN 170)The UV goggles do not provide protection against injuries caused by blue
light beams, therefore switch the LED off when working.
Use the lamps only when they are perfectly safe. Operation is not allowed
when the lamp, supply lines or operating parts are visibly damaged.
Fig. 1: Sender/receiver unit
1 Light beam exit
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2 FOR YOUR SAFETY

2.2 Intended use

Devices of the VICOTEC320 series only serve continuous measurement of concentrations of certain gases, visibility and the temperature in the atmosphere in road tunnels.

2.3 Responsibility of user

Only put the VICOTEC320 into operation after reading the Operating Instructions. Observe all safety instructions.If there is something you do not understand: Contact SICK Customer Service.
Designated users
All operators of the VICOTEC320 should be specifically trained on this device, knowledgable of relevant regulatio ns, and able to assess potential hazards related to its operation.
The VICOTEC320 may only be maintained by persons properly instructed on the tasks assigned, possible risks and protective measures.
Operation
The device may only be operated by authorized persons who, based on their training on, and knowledge of the specific device, as well as knowledge of the relevant regulations can assess the tasks given and recognize the hazards involved.
Installing and maintaining
Skilled persons are required for installation and maintenance.
Please observe the information at the beginning of the respective Sections.
Correct use
Only operate the VICOTEC320 according to the intended use (see “Intended use”,
page 10).
Follow all specifications in these Operating Instructions and only operate the
VICOTEC320 as described in these Operating Instructions. Contact your local SICK representative before performing any work described where the information in these Operating Instructions is inadequate or capable of being misunder­stood.
Keep passwords in a separate, safe place and secure against unauthorized use.Pay attention to the prescribed maintenance work.Do not change any settings on or in the device and do not modify any components when
such changes are not described in these Operating Instructions or in documents referred to in these Operating Instructions.
Special local requirements
Observe the local laws, regulations and company internal operating instructions
applicable at the installation location.
Retention of documents
10
These Operating Instructions:
Must be available for reference.Must be passed on to new owners.
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3 Product description

3.1 Product identification

Product name: VICOTEC320
Manufacturer:

3.1.1 Type plate

The type plate is located at the following positions:
Device Type plate location
Sender/receiver unit
Reflector
Connection unit
PRODUCT DESCRIPTION 3
SICK AG Erwin-Sick-Str. 1 · D-79183 Waldkirch · Germany
Outside: Next to the connections Inside: At the bottom of the left enclosure side
Outside: Next to the connections Inside: At the middle of the right enclosure side
Outside: At the top of the right enclosure side Inside: Next to the connections
Fig. 2: Type plate
1 Device name 2Type code 3Voltage supply 4 Max. power input according to IEC61010-1 5Bar code 6 CE label 7 China RoHS 8 Degree of protection (IP code) 9 Ambient temperature 10 Serial number 11 Material number 12 Company logo
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3 PRODUCT DESCRIPTION

3.2 Product features

Fast, representative local measurement
Very low detection limits for NO and NO
Automatic function monitoring and zero adjust
Independent maintenance prompt when contaminated
Very sturdy design: IP 69K, stainless steel 1.4571
Compatible to assembly consoles and measuring path lengths of the VICOTEC 410 from
SICK

3.3 Device variants

The following device variants are available depending on the measuring task and the application:
Variant Measured components
VICOTEC 321 Measurement of visibility and NO
VICOTEC 322 Measurement of visibility and NO
VICOTEC 323 Measurement of visibility, NO and NO
VICOTEC 325 Measurement of visibility, NO, NO2 and NOx (option: CO)
2
2
2
The device variants differ with respect to the following:
Measurable components
Connection unit interfaces
The sender/receiver unit and the reflector are available for the following measuring distances:
10 m
The connection unit is available with the following interfaces:
Analog/digital
Ethernet
The connection unit can contain an optional CO sensor (electrochemical cell)

3.4 Special features

Operating hour meter for sender lamp and logbook function
High-precision adjustment through automatic mirror tracking
Integrated ambient temperature measurement
Reflector, heated
Communication via CAN System bus or Ethernet (optional)
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3.5 Layout and function

PRODUCT DESCRIPTION 3
Fig. 3: Layout of measuring device components
1Reflector 2 LED matrix to signal automatic beam tracking 3 Sender/receiver unit 4 Dust protection tube 5 Connection unit 6 Plug connections

3.5.1 Functional principle

The VICOTEC320 is a sensor system for continuous measurement of NO, NO (option) concentrations as well as visibility and temperature in road tunnels.
The following functional principles are used:
NO, NO
CO: Electrochemical cell
Visibility: Transmission measurement with blue LED
: DOAS (Differential Optical Absorption Spectroscopy)
2
and CO
2
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4 PROJECT PLANNING

4 Project planning

4.1 Assembly project planning

4.1.1 Arrangement along the tunnel section

The number and distribution of measuring points depends on the ventilation system used. Single factors are:
Type of tunnel profile
Section route
Ventilation system design
Number and arrangement of fans
Regional regulations
Measuring point selection depends primarily on the following criteria:
A combination of VICOTEC320 with VICOTEC 410 or VISIC100SF is recommended for
optimum measuring results.
The recommended distance between visibility measurements depends on whether
these are also to be used for smoke detection: – Without smoke detection: 400 m – With smoke detection: 150 m
We recommend VISIC50SF for smoke detection.
An even spread along the tunnel length is recommended for semi and transverse
ventilation, with at least 2 measuring points per ventilation section.
NO/NO
preferably at the tunnel exit in tunnels with one-way traffic.
Two-way traffic can still arise in tunnels with one-way traffic. It is therefore recommended
to install at least 3 measuring points for visibility in tunnels with lengthwise ventilation: one each about 150 m from the entrance and at least one in the middle of the tunnel.
It is recommended to install additional fog sensors (e.g. VISIC620) near the tunnel
portals when there is a risk that fog can be sucked into the tunnel. Dust particles acting as additional condensation crystals can strengthen the fog effect in the tunnel sections. Fog moisture overlays visibility due to dust particles. Fog sensors serve to prevent fog drifts being sucked into the tunnel. Alternately, visibility can be measured at the tunnel portals using measuring devices (e.g. VISIC100SF or VICOTEC450) that heat the air sucked in and therefore evaporate fog moisture.
When the tunnel roadway curves, ensure that the measuring beam between single
sensors is not interrupted by the tunnel wall, fixtures or vehicles passing each other (see
see “Arrangement with special prerequisites”, page 16).
can be measured every 400 – 1000 m. Position the measuring points
2

4.1.2 Arrangement in cross-section profile

Particle concentration distribution in a tunnel is generally very even across the profile cross-section during traffic movement. Traffic flows and lengthwise flows through natural ventilation and the piston effect of vehicle movement in separate tunnel sections for each direction effect rapid swirling of the air in the tunnel. The turbulence behind vehicles strengthens this effect.
The height is not critical due to excellent swirling. A fitting height between 2.8 and
4.5 meters is aimed at. The sensors contaminate faster when fitted lower and the maintenance effort increases when the sensors are fitted higher.
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PROJECT PLANNING 4
VICOTEC
320 sensor
2.8 … 4.5 m
400
Fig. 4: VICOTEC320 fitting height
Fitting location selection of the respective sensor pairs depends primarily on the following criteria:
Mount the sensors at a safe distance from traffic movement (see for example Section 2
of the German “Richtlinie für die Ausstattung und den Betrieb von Straßentunneln RABT”, version 2006 (Regulations governing equipping and operating road tunnels)).
Good access for maintenance and checking work must be ensured. Locate the sensors
in a protected recess when possible.
Do not locate sensors in close vicinity to ventilators or in the fresh air flow from blowout
units so that the measured value records the effective concentration ratios.
The measuring beam must run lengthwise between sensors and must not be hindered
by fixtures or vehicles passing each other. Fixtures that shine (e.g. emergency exit signs) should be at least 1 m from the optical axis.
No reflecting paint should be on the wall between sensors.
Maintain a distance of 10
Plan sufficient clearance to be able to flap or remove the enclosure cover.
Measured values of gases are kept constant at first when the light beams are interrupted. A malfunction message is sent to the evaluation unit when interruptions last lo nger than two minutes.
±
0.1
m between both sensors.
Fitting options:
Both sensors on a wall in a recess (recommended).
Both sensors on a wall above the side strip; requires safety measures for maintenance
work in cramped conditions.
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4 PROJECT PLANNING
A
R
1
A
R
2

4.1.3 Arrangement with special prerequisites

Tunnel curvature
The sensors can be used with tunnel curvatures up to the following curve radiuses:
Measuring section (A) 10 m
Inner radius (R
Outer radius (R
) Min. 58 m
1
) Min. 147 m
2
Fig. 5: Fitting sensors on the inner curve wall
Fig. 6: Fitting sensors on the outer curve wall
Tunnel with sound insulation wall
Provide appropriate assembly bases onsite when fitting sensors on a tunnel wall with sound insulation.
The assembly bases must provide a firm base suitable for reliable sensor fitting.
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PROJECT PLANNING 4
Fig. 7: Fitting sensors with sound insulation
1 Sound insulation

4.2 Electrical installation project planning

Observe the relevant safety regulations during all installation work. Take suitable protective measures against all possible local risks or those arising in connection with the system (see “For your safety”, page 9).
Sender/receiver unit (2) must always be fitted on the left (see Fig. “Sensor arrange-
ment”, page 18), so that visor (4) is accessible.
Position connection unit (1) so that it can be connected to the sender/receiver unit with
a 1 m long cable.
It must be possible to separate every device singly from the power supply system, e.g.
using a switch or circuit breaker.
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4 PROJECT PLANNING
Fig. 8: Sensor arrangement
1 Connection unit 2 Sender/receiver unit 3Reflector 4Visor A Measuring path (10 B Max. 0.7 m (cable leng th max. 1 m)
B A
±0.1
m)
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5 Installation

5.1 Tools required

Apart from standard tools (such as drill, water level, tape measure), you also need the following tools for the installation:
–8 mm drill bit –15 mm drill bit –Blowout pump for dowel holes –18 mm Allen key –19 mm Allen key –Jaw wrench, 22 mm –Torque wrench –Rubber or plastic hammer – Two laser adjustment units (see “Accessories”, page 68)

5.2 Material required

– 2 stainless steel assembly consoles incl. fixing accessories – Connection lines (see “Connection lines”, page 26)
INSTALLATION 5

5.3 Preparing the installation location

CAUTION: Accident risk through inadequate fastening of the device
Consider the weight of the device when selecting fastenings.Check the load capability/state of the wall/rack on which the device is to be fitted.
Preparatory actions
Secure the place of workProvide adequate lighting and powerProvide a jack lift or stable ladder with clearance to wall

5.4 Transport

Only use the packing provided by SICK to transport sensors. Warranty claims are void when this is not observed. The packing can be obtained from SICK free of charge when required.

5.5 Scope of delivery

Included in scope of delivery:
Sender/receiver unit (incl. screws for fastening on assembly console)
Reflector (incl. screws for fastening on assembly console)
Connection unit (incl. dowels and screws for wall fitting)
Connection lines from the connection unit to the sender/receiver unit and to the
reflector
Protective covers
Keep protective covers. Use protective covers when the equipment is put out of operation for a short time (e.g. during tunnel cleaning).
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5 INSTALLATION
Not included in scope of delivery:
Stainless steel assembly consoles for the sensors

5.6 Assembly

Assembly work must only be carried out by skilled persons familiar with the assembly work.

5.6.1 Fitting the assembly consoles

The assembly consoles comprise 3 parts:
Fig. 9: Assembly console
1 Wall holder for wall fitting 2 Angle bracket to fasten the sensor 3Angle bracket screws
Two angle bracket screws fasten the wall holder and the assembly console together. The angle bracket can be swiveled up to ±7.5° to compensate any assembly unevenness.
Observe the following points during assembly:
Observe local valid safety measures.Only use high-strength and absolutely non-corrosive fastening material made of
stainless steel because the tunnel atmosphere is highly corrosive.
Ensure there is enough space to remove the tube and device cover.Keep the length of the measuring section as exact as possible. Record small
deviations in the Assembly protocol.
Mount both assembly consoles at the same height. Height differences in the optical
axis can be compensated later by swiveling the angle bracket.
Align both assembly consoles at the same tilt angle to the tunnel wall. Different tilt
positions to the tunnel profile make the following sensor alignment difficult. Insert washers under the wall holder when necessary.
Procedure
1 Determine the installation location for the assembly consoles according to the project
planning.
2 Drill the wall holder openings according to the Drilling plan, see see Fig. “Wall holder
assembly drilling plan”, page 21.
3 Insert dowels or wall ties according to the manufacturer's assembly specifications (walls
must be made of at least C20/25 to C25/30 concrete).
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INSTALLATION 5
105105
210210
A
182
182
15
0
15
0
15
0
15
0
15
0
15 x 50
+2
0
15
0
4 Screw the wall holder on and tighten the screws with 70 Nm according to the
manufacturer's assembly specifications, use a torque wrench as necessary.
5 Screw the consoles on provisionally at first.
Fig. 10: Wall holder assembly drilling plan
Tolerances for measuring path A
±0.1
m
10

5.6.2 Fitting the VICOTEC320 sensors

1 Position the sender/receiver unit on the left assembly console and screw it on lightly
with both the retaining screws included in the delivery.
2 Position the reflector on the right assembly console and screw it on lightly with both the
retaining screws included in the delivery.
3 Screw a laser adjustment unit on each sensor above the tube using both knurled-head
screws.
Fig. 11: Laser adjustment unit
1 Crosshair 2Knurled-head screws 3 Adjustment laser
WARNING: Laser class 2
Laser radiation – do not look in the beam.
4 Switch on the laser adjustment unit on the reflector.
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5 INSTALLATION
5 Align the sensor horizontally so that the laser beam strikes the vertical line of the cross-
hair of the other laser adjustment unit see Fig. “Laser adjustment unit”, page 21). To do this, tap very lightly against the front lower edge of the sensor enclosure with a rubber hammer (see Fig. “Horizontal sensor alignment”, page 22).
Fig. 12: Horizontal sensor alignment
1 Retaining screws 2Angle bracket screws
6 Tighten both retaining screws of the sensor with 45 Nm, use a torque wrench as
necessary.
7 Slightly loosen the angle bracket screws. 8 Align the sensor vertically so that the laser beam strikes the horizontal line of the cross
hair of the other laser adjustment unit (see Fig. “Laser adjustment unit”, page 21). To do this, tap very lightly against the front lower edge of the angle bracket with a rubber hammer (see Fig. “Vertical sensor alignment”, page 22).
22
Fig. 13: Vertical sensor alignment
9 Tighten the angle bracket, use a torque wrench as necessary. 10 Check again whether the laser beam strikes the crosshair and correct as necessary. 11 Switch the laser adjustment unit off.
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12 Repeat steps 5 to 11 on the opposite sensor and laser adjustment unit.
105105
210210
A
182
182
15
0
15
0
15
0
15
0
15
0
15 x 50
+2
0
15
0
13 Unscrew and remove the laser adjustment unit.

5.6.3 Fitting the connection unit

Position the connection unit so that it can be connected to the sender/receiver unit with the 1 m long cables.
1 Determine the installation location for the connection unit according to the project
planning.
2 Drill the openings according to the Drilling plan, see Fig. “Connection unit assembly drill-
ing plan”, page 23.
3 Insert dowels or wall ties according to the manufacturer's assembly specifications (walls
must be made of at least C20/25 to C25/30 concrete).
4 Screw the connection unit on.
INSTALLATION 5
Fig. 14: Connection unit assembly drilling plan
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