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® ROTALIGN Operating Instructions Alignment Handbook Dear Customer, If you have any suggestions for improvement or corrections (not just for this manual, but also for software or hardware), please give us a call or drop us a line! We would be glad to make improvements wherever possible.
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Foreword Congratulations on your decision to align your machine shafts with ROTALIGN! We have built on ten years of experience in laser alignment with OPTALIGN plus two years of experience with RO- TALIGN. With feedback from customers such as yourself, we have developed a system which offers unprecedented ease of use with many new features: •...
Contents Chapter 1: Introduction This chapter includes general information regarding the ROTALIGN system and its operation including, in particular, the intended use and safety information. Chapter 1 Introduction ......... 1-1 to 1-10 Contents ..................1-1 The ROTALIGN package ..............1-2 Before you start! ................
The ROTALIGN package The ROTALIGN package ALI 3.500 ALI 3.500EX 2.891set ALI 3.585 ALI 3.610 ALI 3.600 ALI 3.550 The ROTALIGN package contains the following items: (Please see page 1-6 for further information on the intrinsically safe version ALI 3.500EX.) ALI 3.585 ROTALIGN Case (ABS, black), complete with key and combination locks (page 6-14).
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The ROTALIGN package ALI 3.588 ALI 9.454G ALI 9.454G 90109 ALI 2.800 ALI 3.608 ALI 3.581-2 ALI 3.588 Tape measure, mm/inch (page 4-21) ALI 9.454G ROTALIGN Short Instructions ALI 9.381G ROTALIGN Operating instructions ALI 2.800 6x 1.5 V alkaline battery (IEC LR 14 / size "C") (MAIN BATT) in computer (page 2-9) 90109 9 V battery (6LR 61)
Before you start! Before you start! Welcome to the ROTALIGN instruction manual and alignment handbook! The ROTALIGN alignment procedure is intended to be straightforward with self-explanatory diagrams and messages on the computer screen to show what's going on - so that you shouldn't have to consult this manual too often! Everyone Please acquaint yourself first with the important notes and safety,...
Safety and operating information Safety and operating information This section contains the most important information regarding the safe operation of the ROTALIGN alignment system. Before using the system, you must first familiarize yourself with this section, in particular, the safety information. Symbols The following symbols are used in this handbook to call your attention to important sections of text.
Safety and operating information Safety information The following information must be observed to ensure the safe operation of the ROTALIGN. General • Before starting up the machines, all ROTALIGN components must be removed from the shaft (or coupling). Otherwise, serious bodily injury may result from flying parts! WARNING! •...
Safety and operating information Laser safety The ROTALIGN system uses a Ga-Al-As semiconductor laser, classi- fied as a Class II laser. These lasers comply with the requirements outlined in the USA's FDA specification 21 CFR Ch. 1, Parts 1040.10 and 1040.11 as well as the ANSI standard. ROTALIGN also fulfills British standard BS 4803 (Part 1 to Part 3) and European Industrial Standard IEC 825.
Safety and operating information Operating information In order to ensure proper operation of the ROTALIGN system, observe the following information: Temperature range The ROTALIGN system must be used at temperatures between 0° and 45° C (32° to 113° F). Outside of this range, the specified accu- racy may not be maintained.
Safety and operating information Incident light and other sources of interference Avoid exposing the ROTALIGN computer to strong, hot light such as direct sunlight: the pixel display can act as a solar collector (at a rate of 10 watts!) and turn dark (reversibly) if overheated. Mobile radio communication equipment should not be used near the system, as it may interfere with measurements.
Chapter 2: Description Chapter 2: Description This chapter includes a description of the ROTALIGN and its compo- nents. Chapter 1 Introduction ......... 1-1 to 1-10 Chapter 2 Description ........2-1 to 2-16 ROTALIGN overview ..............2-2 The ROTALIGN Computer ............. 2-3 The ROTALIGN keyboard and screen .........
ROTALIGN overview ROTALIGN overview Laser Receiver Compact chain-type bracket ROTALIGN Computer The ROTALIGN system mounted across a machine coupling The ROTALIGN laser alignment system: BRACKETS used to mount the laser and receiver securely on the shaft on either side of the machine coupling*. LASER fitted to the machine shaft on one side of the machine coupling, shines a beam across the coupling*.
The ROTALIGN computer The ROTALIGN Computer ALI 3.550 The heart of the ROTALIGN system is the ROTALIGN computer, built to rugged industrial standards of shock and water resistance. It contains a complete desktop computer with LCD display and numer- ic-function keypad. Names and letters can be entered where neces- sary with a special on-screen character table.
The ROTALIGN computer The ROTALIGN keyboard and screen ..BATT....... MAIN AUX CHARGE SLEEP Status line Gives a short explanation of the current screen or instructs the user what to do next. Function softkeys Labelled at the bottom of the display, these keys are defined by the program according to the situation at...
The ROTALIGN computer Computer program operation The ROTALIGN computer program is intended to be easy to use, even for a computer novice. Feel free to experiment with the keys and options as no physical harm can come to the computer. All the screens (except the first) have a status line at the top giving simple instructions.
The ROTALIGN computer Indicator LEDs Four indicator LEDs above the computer display provide useful information on the operating status of the computer: ..BATT....... MAIN AUX CHARGE SLEEP "MAIN" lights to indicate that the main battery is becoming depleted. In that case, replace the batteries or connect the AC power supply to the computer as soon as possible.
The ROTALIGN computer Interfaces The ROTALIGN unit is fitted with four interfaces: for the measure- ment signal from the receiver, data exchange with a PC, printer connection and power supply. Connecting the receiver The receiver is connected via cable ALI 3.581-2 to the socket on the top end of the ROTALIGN computer as shown below.
The ROTALIGN computer Connecting PC, printer and mains supply A 9-pin serial port (RS232) is installed in the ROTALIGN unit for connecting to a PC. Using this port, measurements can easily be documented and backed up on a PC. From the main menu (reached by pressing the Menu key), select the "RS 232 CONFIG"...
The ROTALIGN computer Batteries and power supply ROTALIGN offers you four different possibilities for power supply to the computer, which in turn powers the measurement receiver: 1. Six standard "C"-size (IEC LR 14) alkali-mangan batteries is the standard option as the main battery supply, accessed via the upper left panel of the computer housing.
2-10 The ROTALIGN computer Main battery depletion When the main battery becomes depleted, the red "MAIN" LED in the upper-left corner of the ROTALIGN illuminates. The ROTALIGN then starts to draw power from its auxiliary battery (described next), and can operate for an additional 20-40 minutes before the auxiliary battery is also depleted.
2-11 The ROTALIGN computer Auxiliary battery The ROTALIGN computer also contains a 9 V AUXILIARY battery which can run the computer when the main power supply is depleted or being changed. It will run ROTALIGN for between 20-40 minutes which should be ample time to change the main battery or connect the charger.
2-12 The ROTALIGN computer Power-saving features and "Sleep mode" The ROTALIGN computer automatically monitors its operation so that it can save battery power by shutting itself down temporarily when not in use. This is not operational when using the AC charger. •...
2-13 ROTALIGN components ROTALIGN components in detail On the following pages are descriptions of the main ROTALIGN components. Laser ALI 3.610 The semiconductor laser diode emits a ray of red light (wavelength 675 nm) which is visible where it strikes a surface. The beam is emitted with a diameter of approx.
2-14 ROTALIGN components Laser battery The ROTALIGN laser is powered by a single 9 V battery (type IEC 6LR61) which, depending on battery make and operating pat- terns, provides a typical operating duration of 80 hours. Note, Lithium batteries of this size can also be used, increasing operation up to 150 hours.
2-15 ROTALIGN components Receiver ALI 3.600 The receiver contains two position detectors, located one behind the other, which measure the exact position of the laser beam as the shafts are rotated. The detectors are biaxial, analog, photoelectric semiconductor position detectors with a resolution of better than 1 µm / 1/1000 mm (or 0.04 mils) and an area of 18 mm x 18 mm / 0.7"...
2-16 ROTALIGN components Compact chain-type bracket ALI 2.891 set Compact and lightweight, this bracket is designed to provide ex- tremely rigid support for the measurement components with a minimum of mounting time and effort. The compact chain-type bracket fits onto shafts and couplings ranging from 15 to 500 mm (1/ 2"...
Chapter 3: Configuration and data management Chapter 3: Configuration and Data Management This chapter includes instructions for configuring the ROTALIGN and managing data, i.e. saving, storing, opening files etc. Chapter 1 Introduction ......... 1-1 to 1-10 Chapter 2 Description ........2-1 to 2-16 Chapter 3 Configuration and Data Management ......
Configuration and data management overview Configuration and data management overview CONFIGURATION (page 3-3) EDIT: Units mm/inch Language English/German/French/Spanish/Dutch/ Swedish/Japanese/Finnish Runtime (time before "sleep") Sleeptime (time before switch off) Sensorport "Default"/COM CONTR (screen contrast) DATE (Enter date, time & select format) USER SETUP (see below) USER SETUP (page 3-4)
Configuration Configuration The CONFIGURATION option is available from the introductory screen, page 4-14, with the CONFIG softkey as well as from the MENU for both horizontal and vertical machines: Use the arrow key to highlight one of the top five options, then press EDIT to change the setting: UNIT selects between inches and mm.
User setup User setup USER SETUP allows you to type in the company and plant names, location, user name, a comment and machine names: The User Setup file is used as the default for new measurements. The data entered in this file is stored in a given measurement file when it is saved for the first time.
Data management Data management Select FILE from the Menu to call up a menu of file, printer and interfacing options: NEW clears all current data ready for a new alignment job and puts you in the dimensions mode. If the current data have not previously been saved, then the message appears "Current data not saved.
Data management SAVE saves the current data with the following file-naming rules: 1) If the current file is new and does not yet have a name, the computer suggests a default numerical name (sequential, start- ing with 01). You may either accept this name by pressing OK or press the SAVE AS key, discussed below, and enter a name up to 8 characters in length.
Data management REPORT REPORT prints an alignment report showing machine setup and dimensions, measurements and movements. There are two types of report, either text (TEXT REPORT) or a printout of text with graphics (GRAPH REPORT). File type (horiz. or vert. machine) Note, only the files are shown for the current application (i.e.
Data management PRINTER CONFIG Use PRINTER CONFIG to select the printer type and connection. If your printer name is not shown, either select a similar model from the same manufacturer or find out with which type your printer is compatible (commonly with EPSON FX series, for example). Selected port (see below) Selects printer connection, either LPT (parallel, the lower socket on the side of...
Chapter 4: Horizontal Alignment Chapter 4: Horizontal Alignment This chapter includes instructions for aligning horizontal machine arrangements. A description of the Q alignment mode is UICK HECK given first, followed by instructions for the more thorough standard horizontal alignment mode. Chapter 1 Introduction .........
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Operation overview Deactivating stray measurements ......... 4-41 Options during measurement ........... 4-43 XY VIEW ................4-43 AVERAGE ................4-44 CURVE FIT ................4-45 RANGE EXTENSION ............. 4-46 TABLE ................... 4-48 8. Results .................. 4-49 9. MOVE ................... 4-51 ZOOM ................... 4.52 Vertical movement ..............
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Quick Check quick UICK HECK check is a quick alignment measurement for standard horizon- UICK HECK tal machines. It is, as it says, QUICK, with semiautomatic operation, and a CHECK, without special options. These brief instructions are intended for a user with some experience of alignment, e.g.
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UICK HECK quick UICK HECK check 1. Set up ROTALIGN Prepare the machines for alignment (see page 4-10 for details. In particular, rigid couplings (e.g. turbines) must be loosened so as not to exert any force on the shafts. Mount the laser and receiver on the coupling with the laser on the left (stationary) machine (page 4-12).
UICK HECK 3. Adjust beam and measure The measurement screen appears. Switch on laser and center the beam onto the receiver dustcap with the two thumbwheels on the laser. Remove the dustcap and view the target on the screen (page 4-23): Adjust laser, press START to measure CENTERED!
MENU overview - horizontal machines Menu overview - horizontal machines MACHINE SETUP (page 4-17) Select machine & coupling types Normal 4 feet 6 feet Single bearing V form Stationary (left machine only) L ? R (select which machine) EDIT NAME (enter a name for each machine) CPLG TYPE (see below)
The Menu The Menu The Menu key can be used to call up a screen displaying the available functions for the current alignment mode (i.e. horizontal or verti- cal—no menu is available for the Q mode). On the opposite UICK HECK page is an overview of the ROTALIGN functions which relate directly to horizontal machine alignment and the locations of the functions in...
Horizontal machine alignment Horizontal machine alignment The ROTALIGN program covers practically any alignment situation. A multitude of options are available with the softkeys at the bottom of the screen. For most applications though, the "straight through" approach should apply where the default settings are perfectly suitable and the special options are not required.
4-10 Horizontal machine alignment - prepare the machines 1. Prepare the machines Before using ROTALIGN, make sure the machine is properly prepared for alignment as described below. See page 6-7 for further informa- tion. Ensure that the machine cannot accidently be started before commencing work.
4-11 Horizontal machine alignment - mount the brackets 2. Mount the brackets Mount the brackets on either side of the machine coupling, and both at the same angle. Here is how to fit the compact chain-type brackets: 1. Choose the shortest support posts which will still allow the laser Note: Tighten the support posts beam to pass over the coupling flange.
4-12 Horizontal machine alignment - mounting laser and receiver 3. Mounting laser and receiver Install the laser on the support posts of the bracket installed on the shaft of the machine on your left (as viewed from normal working position). Note: The cable should be permanently connected to the receiver, also during storage, to save wear and tear on the compo- nents.
4-13 Horizontal machine alignment - mounting laser and receiver Connecting the receiver Important : "pull, don't twist" the Insert the straight-ended cable cable when disconnecting. plug into the eight-pin socket on PRÜFTECHNIK advises leaving the the top of the computer housing cable connected to the ROTALIGN at all times, even when in its case.
4-14 Horizontal machine alignment - switch on the computer 4. Switch on the computer Press the ON/OFF key to switch on the ROTALIGN computer. Wait about 10 seconds for the program to load. The opening screen then appears: Select Units, inch/mm opposite Select language Set screen contrast...
4-15 Horizontal machine alignment - switch on the computer Select horizontal alignment Press the softkey marked with the coupled horizontal shafts to enter the standard horizontal machine alignment application. Hints on using the program The ROTALIGN computer program is intended to be easy to use— even for a computer novice.
4-16 Horizontal machine alignment - machine dimensions 5. Machine dimensions After selecting the Horizontal machine application, the computer displays a diagram of the machines to be aligned and prompts for the machine dimensions. (You can also reach this screen from elsewhere in the program at any time by pressing the DIM key.) The default arrangement is: •...
4-17 Horizontal machine alignment - machines dimensions Machine setup The MACHINE SETUP can be selected from either the Dimensions screen with the OPTION softkey (see page 4-16) or from the Menu. OPTION OPTION Machine Setup allows selection of horizontal machine and coupling types, and you can give each machine a reference name.
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4-18 Horizontal machine alignment - machine dimensions 2. Press EDIT NAME to call up the Text Editor (described in detail EDIT on page 3-4). Use the softkeys to select a name up to 10 NAME characters long, e.g. "MOTORXX101" or "FEEDPUMP." When finished, select "exit"...
4-19 Horizontal machine alignment - machine dimensions Coupling type Before entering the dimensions, select the coupling type. This can be CPLG OPTION TYPE selected from either the Dimensions screen with the OPTION and CPLG TYPE softkeys (page 4-16), or from the Menu. Selecting a coupling type allows the program to calculate and display the alignment conditions appropriate to your machine.
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4-20 Horizontal machine alignment - machine dimensions CHANGE MODE selects the way the coupling misalignment will be CHANGE displayed. This allows depiction of results in the same format as that MODE specified by the machine manufacturer. The format selection de- pends on which type of coupling you have, thus: Angles are given in millirads (mrad) where:...
4-21 Horizontal machine alignment - machine dimensions Enter the dimensions • Tape measure readings are perfectly sufficient for determining dimensions. In the status line is shown which dimension to enter, and whether you are in inch or mm mode. To change the units, press the M key and select "Configuration"...
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4-22 Horizontal machine alignment - machine dimensions The dimensions you need to enter vary according to machine and coupling types. In the default mode proceed as follows: 1. Enter the coupling diameter If it's easier to measure the coupling circumference, use the ÿP softkey Pi symbol, by typing:...
4-23 Horizontal machine alignment - laser beam adjustment 6. Laser beam adjustment Press the "M" key to start the measurement process. When first mounted, the laser and receiver may be misadjusted. The laser and receiver must then be adjusted to direct the laser beam into the middle of the receiver housing aperture.
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4-24 Horizontal machine alignment - laser beam adjustment 3. Use the lower thumbwheel on the laser housing to adjust the lateral position of the laser beam. The beam spot should now strike the center of the cap covering the receiver aperture. 4.
4-25 Horizontal machine alignment - laser beam adjustment 5. Remove the cap or beam tube from the receiver. The computer display should resemble that pictured below. CENTERED! Details of these softkeys on page 4-28 The target diagram in the left portion of the display represents the FRONT position detector within the receiver (there are two detectors, see page 2-15).
4-26 Horizontal machine alignment - laser beam adjustment The two detectors can be seen in this display. The beam should be centered in both planes which may require using the thumb- wheels. It some cases it may be necessary to move the receiver and/or laser along their posts or the bracket may have to be loosened and slightly rotated.
4-27 Horizontal machine alignment - laser beam adjustment Why centered AND perpendicular? If the laser and receiver are not reasonably in-line, the beam could be centered on one detector and off center on the other: Front detector Rear detector centered off-center Laser and receiver not in-line (exaggerated...
4-28 Horizontal machine alignment - measurement 7. Measurement Once the laser beam is adjusted, the alignment can be measured. There are several measurement modes to choose from, the default being "Continuous Sweep." This is the standard and simplest method for measuring alignment, whereby the shaft is rotated and a series of measurements are automatically made during rotation.
4-29 Horizontal machine alignment - measurement Soft foot SOFT FOOT is the condition whereby one or more machine feet are not resting properly on the foundation but are being held down by force with the foot bolts. Soft foot could be a result of: •...
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4-30 Horizontal machine alignment - measurement Soft foot Parallel Angular Procedure: Note: the machine(s) to be checked are assumed to have four feet in an approximately square formation. If your machine has six feet then it should be measured in two parts, first the front four feet, then the rear.
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4-31 Horizontal machine alignment - measurement 3) The Soft Foot screen now appears: Select left/right machine if both are moveable 4) Check that the laser is switched on. If NO LASER or LASER OFF is flashing, then adjust the beam (see page 4-23). 5) Select one of the feet with the softkeys and loosen the corre- sponding anchor bolt.
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4-32 Horizontal machine alignment - measurement Ö– In the above example the correction would be to place a 35 mil (35 x 0.001") shim under foot "b" (the foot with the largest gap)—just like placing a beer-mat under a wobbly bar table! Angular soft foot If one value is significantly higher than the others, then angular soft foot can be suspected:...
4-33 Horizontal machine alignment - measurement Select measurement mode The MEASUREMENT MODE can be selected from either the Enter MEAS Measurement Mode screen with the MEAS MODE softkey or the MODE Menu. This option for horizontal machines allows you to choose the method of measurement and begins actual measurement.
4-34 Horizontal machine alignment - measurement Below follows an explanation of each measurement mode: CONTINUOUS SWEEP This is the simplest procedure for horizontal measurement and is the default method in "Q " (page 4-3), basic horizontal align- UICK HECK ment (page 4-8) and horizontal alignment with two-bolt flanges (page 5-13).
4-35 Horizontal machine alignment - measurement MEASURE AT 0,3,6,9 This method is included for "compatibility" with the OPTALIGN system. This mode does not use the receiver's inclinometer readings to calculate the alignment results. 1. Mark out four clock positions around the shaft by dividing the shaft circumference by four, or you can use an inclinometer of your own if the machine is horizontal.
4-36 Horizontal machine alignment - measurement MULTIPOINT (5 at least) In this measurement mode for horizontal machines only, you rotate the shaft to any desired angles and press TAKE POINT. This is recommended when you have very restricted shaft rotation or if you want to have more control over the measuring points than with the "Continuous Sweep"...
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4-37 Horizontal machine alignment - measurement 3. Mount the laser and receiver. If one shaft is nonrotatable then mount the receiver on it if possible: Receiver on nonrotating shaft, mounted on magnetic sliding bracket If neither shaft can be rotated, the laser and receiver can both be mounted on magnetic sliding brackets.
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4-38 Horizontal machine alignment - measurement 4. Select PASS MODE and align the laser as usual. 5. Press START; the first measurement is immediately taken. Now rotate the receiver (or slide the bracket) by about 60° to the next measuring position. 6.
4-39 Horizontal machine alignment - measurement DIAL GAUGE VALUES This option allows you to calculate equivalent dial indicator values from a laser measurement. After making a set of measurements with any of the horizontal machine measurement modes, press the MEAS MODE softkey and select the DIAL GAUGE option to display the following screen: Radial gauge...
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4-40 Horizontal machine alignment - measurement The calculated dial gauge values are now displayed. These calculated EDIT values are zeroed to the 12 o'clock position: It is also possible enter dial gauge readings and to calculate misalignment and corrections. After entering machine dimension as would be done for any machine, select the DIAL GAUGE option from the MEAS MODE screen.
4-41 Horizontal machine alignment - measurement Deactivating stray measurements If a point on the target display seems somewhat astray, it can be deactivated and remeasured. The first measurement points taken in a given measurement are often victims of "stiction"—resulting from the initial force necessary to overcome static friction.
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4-42 Horizontal machine alignment - measurement As shown below, the deactivated point is indicated by a white circle: Circle shows The "clock" shows which points are deactivated still valid after deactivation point Point deactivated! CENTERED! Press the CLR key to delete all current measurement values. Although this clears the measurement values from memory, thereby speeding up transitions between options in measure mode, the measured results remain visible in the Measure screen.
4-43 Horizontal machine alignment - options during measurement Options during measurement In addition to the aforementioned functions available in the measure- ment modes, several additional features are also provided. Described on the following pages are the XY View and the functions available in the screen and the TABLE option.
4-44 Horizontal machine alignment - options during measurement A thermometer measures the current temperature in the receiver. This value is displayed on the right side of the XY VIEW screen. A warning appears should the ambient temperature fall below or rise above the specified operating temperatures: 0 °C - 60 °C (32 °F - 140 °F).
4-45 Horizontal machine alignment - options during measurement CURVE FIT CURVE Once sufficient measurement data are available, the CURVE FIT option appears in the XY VIEW screen. Displayed in this screen is the YY ellipse, a representation of angularity (X-axis) versus shaft offset (Y-axis).
4-46 Horizontal machine alignment - options during measurement RANGE EXTENSION In rare cases where shaft offset or gap is so extreme that the laser beam "wanders" out of the receiver range during rotation, the laser must be repositioned. The ROTALIGN "EXTEND" option guides you through the necessary adjustment.
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4-47 Horizontal machine alignment - options during measurement 3. Press the START EXTEND softkey to inform the ROTALIGN to START take a reference measurement. "Extending in process!" will EXTEND VIEW appear on the screen. 4. Use the two thumbwheels on the laser to recenter the laser beam. The laser beam should fall within the two centering circles in the ROTALIGN display: CENTERED!
4-48 Horizontal machine alignment - options during measurement TABLE TABLE VIEW Table is a list of up to five measurements made on the same machine. These can be selectively averaged for greater accuracy, especially if you are measuring nonrotating shafts. To select measurements from the list for averaging, highlight each in turn with the arrow key and press SELECT.
4-49 Horizontal machine alignment - results 8. Results Press the R key to display a graph of the alignment condition in ESULT both vertical and horizontal directions: LEFT MACHINE vertical position viewed RIGHT MACHINE vertical alignment viewed from side resting on feet from side and resting on feet VERTICAL ALIGNMENT...
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4-50 Horizontal machine alignment - results Note, the alignment diagram is scaled according to the entered machine dimensions. The smiley faces appear if a tolerance mode has been set, see page 4-62 for details. The calculated misalignment values are displayed In the middle of the screen.
4-51 Horizontal machine alignment - move 9. MOVE MOVE Thanks to its five-axis sensor design, ROTALIGN lets you monitor VIEW alignment corrections on screen as they are being made. If the machine suffers from excessive soft foot, the MOVE function Important: may be hampered by the fact that the machine changes its position on If, approximately 10 seconds...
4-52 Horizontal machine alignment - move Detailed descriptions of the shimming and positioning procedures, including the ZOOM mode, are described on the following pages. Also available in the MOVE mode are XY VIEW, H and V ZOOM and SAVE, described in detail on the following pages. The AVERAGE function, set in XY VIEW screen, is automatically used during Move measurements.
4-53 Horizontal machine alignment - move Vertical movement 1. The accuracy-compromising effects of backlash—caused by tor- sional play between shafts—can be reduced by rotating the shafts so that the sensors are oriented in the move direction. For vertical moves, this means that the sensors should ideally be positioned in either the 12:00 or 6:00 position.
4-54 Horizontal machine alignment - move Horizontal movement Before horizontal positioning is carried out, a new set of alignment readings should be taken due to the fact that machines usually move slightly during vertical shimming. However, this second measure- ment cycle takes relatively little time since the machine dimensions have already been entered: 1.
4-55 Horizontal machine alignment - alignment completion 10. Alignment completion This completes the horizontal machine alignment! If you have had difficulties with a particular alignment, common causes are: Soft foot (page 4-29) Beam play Pipe strain Oil film thickness variation in white metal bearings ...
4-56 Horizontal machine alignment - alignment completion SAVE Saves the file under the current name. If the file has not been given a name, a sequential number starting with "01" will used. A current name will be overwritten without confirmation. Up to 150 files can be stored. PRINTER- Allows you to select your printer from a list.
4-57 Horizontal machine alignment - options during results Options during Results In the Results screen described on page 4-49 are two softkeys not described in the main instructions: OPTION and HISTRY (abbreviat- ed due to space constraints in the ROTALIGN display). OPTION calls up the "Results Setup Options"...
4-58 Horizontal machine alignment - options during results History HISTRY Results can be accumulated for a record of your alignment jobs. Press HISTRY from the Results screen to show this list of results: Returns to the original results display you had before HISTRY was pressed.
4-59 Horizontal machine alignment - options during results Coupling Targets When you select COUPLING TARGETS from the Menu, the Result Setup Options appears as shown on page 4-57. Press the TARGET TARGET softkey which will allow entry of the desired coupling condition for "cold"...
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4-60 Horizontal machine alignment - options during results Shown in the first of the two figures below are the results obtained for a typical pair of machines. At first glance the results appear to be satisfactory and within tolerance: If, however, the following operating specifications for the machines are entered in the Coupling Targets screen, the results are somewhat different: Operating specifications...
4-61 Horizontal machine alignment - options during results Thermal growth When you select THERMAL GROWTH from the Menu, the Result Setup Options appears as shown on page 4-57. Press the THERM THERM GROWTH softkey which allows you to enter the expected thermal GROWTH movements for the nonstatic machines (see page 4-17).
4-62 Horizontal machine alignment - options during results Tolerances The TOLERANCES option allows you to compare alignment results with standard recommended tolerance limits, based on the RPM and machine size, or on your own coupling parameter tolerances. If a tolerance mode is activated, the program shows a happy face when measurements are within tolerance! You can reach the Tolerance option either from the Menu or from the Results Setup Options screen (page 4-57) and the TOL softkey.
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4-63 Horizontal machine alignment - table tolerances TABLE TOLERANCES The tolerances listed in the table are the standard accepted values based on the coupling type and machine sizes you entered in the Dimensions and on the entered RPM value. Shown below is the Table screen for "Excellent values"...
4-64 Horizontal machine alignment - table tolerances When the title USER DEFINED TOLERANCES is displayed, you can EDIT press EDIT TABLE to enter an editing mode : TABLE INIT TABLE resets all the values to equal the "Excellent values." INIT TABLE The arrow keys can be used to navigate in the table.
4-65 Horizontal machine alignment - static feet Static feet STATIC FEET The STATIC FEET option can be selected from either the MENU or from the Results Setup Options (page 4-57). This option allows you to define which pair(s) of feet on the two machines are deemed static, i.e.
Chapter 5: Vertical Alignment Chapter 5: Vertical Alignment This chapter includes instructions for aligning vertical machine arrangements. Also included in this chapter are instructions for aligning flanged horizontal machine arrangements—an arrangement very similar to standard vertical machines. Chapter 1 Introduction ......... 1-1 to 1-10 Chapter 2 Description ........
Vertical machine alignment Vertical machine alignment Vertical machine arrangements typically comprise one machine mounted on top of another and are secured with a bolt flange as shown below: Offset adjustment (in X and Y directions) Angular adjustment with shims around the flange The ROTALIGN laser and receiver are mounted on either side of the coupling as for coupled horizontal machines, with the laser below...
Vertical machine alignment - set up ROTALIGN 1) Set up ROTALIGN Since the ROTALIGN sensor is unable to detect the rotational position of the vertical shaft, it is necessary to mark out a series of angular positions for measurement. This may be done in one of two ways: either the shaft or the coupling housing can be numbered.
Vertical machine alignment - enter dimensions a) As for the shaft numbering method described on the previous page, mark a starting position on the coupling housing close to the shaft and in line with one of the pillars or bolts. Likewise, mark a reference point on the shaft.
Vertical machine alignment - measure c) If the flange is not symmetrical, i.e. · it is rectangular or elliptical, or · the axis is not centered or · there are nonsymmetrical bolts, then these can all be set with OPTION. Please see page 5-11 for more details.
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Vertical machine alignment - measure c) Ensure that the sensors are exactly at the chosen position and press the numeric key corresponding to the position, e.g. "1": Indicates too few measure- ments or too small an angle Screen after one measurement CENTERED! No.
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Vertical machine alignment - measure g) Deactivating stray measurements: if a point on the target display seems somewhat astray, it can be deactivated and remeasured: 1) Use the ARROW softkey to highlight the rogue point with a cross; 2) Press the "–" key. The point will be deactivated and displayed as a small circle.
Vertical machine alignment - results 4) Results When measurement is complete, press the "Results" key: Page 3-6 These are the alignment corrections. The display shows the flange viewed from above. The first measurement position is at the top of the screen. On the left portion of the screen are the offsets: in the above example these are 0.29 mm towards the back and 0.12 mm to the right.
5-10 Vertical machine alignment - move horizontally 6) Remeasure If flange has drifted horizontally, it is necessary to remeasure. Press the "M" key and remeasure as before. 7) Move Horizontally The machines can now be aligned horizontally: press MOVE to MOVE show the following screen: Angle (corrected with shims)
5-11 OPTION: Nonsymmetrical flange shape OPTION: Nonsymmetrical flange shape OPTION From the Vertical dimensioning screen you can select OPTION to set up a nonsymmetrical flange: Altering a rectangle or ellipse Press option to change the overall flange dimensions: Use the arrow key to highlight the Y-AXIS (front to back) or X-AXIS (along the front) dimensions then press EDIT to change them.
5-12 OPTION: Nonsymmetrical flange shape - moving or deleting bolts Moving or deleting bolts Press EDIT BOLTS to show this screen: EDIT BOLTS To the right is the bolt list showing each bolt, its number and its X and Y coordinates. Browse through the list with the arrow keys; the corresponding bolt is highlighted on the diagram.
5-13 Flange-mounted horizontal machines Flange-mounted horizontal machines When machines are joined by means of flange, their alignment is determined by inserting the proper combination of shims at the flange bolts and, depending on the flange type, at the sides of the flange.
5-14 Flange-mounted horizontal machines 2) Enter dimensions a) The flange dimension screen appears as shown below: b) The default bolt pattern is circular. Press CIRCLE/SQUARE once CIRCLE to change this to a circular bolt pattern within a square flange SQUARE (see page 5-11).
5-15 Flange-mounted horizontal machines e) Press the arrow key to proceed to the distance between coupling center and ROTALIGN receiver. Key in this distance and confirm with the ENTER key. 3) Measure Since the flanged machines under consideration here are mounted horizontally, a wider choice of measurement methods is available.
5-16 Flange-mounted horizontal machines 4) Results When you have finished taking measurements, press the R key: ESULTS The flange is depicted as viewed from the right machine toward the left. The bolts in the figure correspond to the bolts (or shimming positions) on the flange, with the top position marked "1."...
5-17 Flange-mounted horizontal machines 7) MOVE to eliminate offset Press the softkey marked "MOVE" to start the offset correction MOVE function. Rotate the shafts such that the sensors are located at bolt position number 1 (the top position for horizontal shafts; see step 4 above), then press the "START"...
Chapter 6: Appendix Chapter 6: Appendix This chapter provides background to alignment and tolerance meth- ods. To assist you in identifying and rectifying errors, a troubleshoot- ing guide and list of error messages are also included. Following an extensive list of ROTALIGN accessories is a discussion on soft foot diagnosis.
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Chapter 6: Appendix Practical examples of thermal growth entries ......6-32 Thermal growth for stationary machine ........6-33 Special case: parallel growth ............ 6-34 Technical specifications ............6-35 Warranty, service and care............6-36 Warranty ................... 6-36 Service and care ............... 6-36 Index ...................
Shaft alignment in theory and in practice What is "alignment?" Two machines are aligned with one another when the rotational axes of both shafts are colinear during operation. The following chart shows the possible deviations from this ideal condition: Offset Vertical Horizontal misalignment...
Shaft alignment in theory and in practice Comparison of alignment methods Straightedge The straightedge is the most well-known and widespread shaft alignment tool. If both the coupling surface and the mea- Measurement suring eye are in good condition, align- Messen 5 mils ment accuracy may approach 1/10 mm (5 mils).
Shaft alignment in theory and in practice How accurate should alignment be? The suggested alignment tolerances shown at right are general values based upon experience and should not be exceeded. They are to be used only if existing in-house standards or the manufacturer of the machine or coupling prescribe no other values.
Shaft alignment in theory and in practice Machine preparation Certain preparations should be made before beginning any alignment to ensure efficient measurement and successful results. Ensure that the machine cannot accidently be started before commencing work. WARNING! Solid, flat foundation A solid, rigid foundation is required to obtain correct, lasting shaft alignment that allows long-term uninterrupted machine service.
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Shaft alignment in theory and in practice Coupling play Thanks to its five-axis detector When coupling play is suspected: For maximum accuracy during soft system, ROTALIGN can distin- foot measurement and alignment guish between coupling torsion adjustment, the shafts should be play (backlash) and true shaft rotated so that the sensors are misalignment, so that even un-...
Shaft alignment in theory and in practice Shims Proper shims must be used for satisfactory alignment results based upon ROTALIGN shimming corrections. What constitutes a "proper" shim? First, its thickness must match the correction values (within 0.025 mm, [1 mil] since shimming stock is not made thinner than this).
6-10 Shaft alignment in theory and in practice The ROTALIGN measurement principle To measure the misalignment, the shafts are rotated. The laser beam shines onto the receiver detector, and during rotation any misalign- ment in the shaft causes the laser beam to change its position in the receiver.
6-11 Troubleshooting guide Troubleshooting guide Here is a list of possible problems encountered with ROTALIGN. See also the Error messages on page 6-13. Computer will not switch on: Replace Main batteries (page 2-10) or connect charger (page 2-8). If this doesn't help, replace the Auxiliary battery (page 2-11) as well. If there is still no response and you are quite certain that the replacement batteries are new, contact your local PRÜFTECHNIK distributor.
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6-12 Troubleshooting guide Inconsistent measurements: 1) Brackets incorrectly mounted: are the brackets slipping or loose or mounted at an angle? (page 4-11). Were the brackets accidentally knocked during or between measurements? 2) Measurement range too small or too few points: rotate through a larger angle with more measurement points (page 4-33) 3) Machine preparation problem: excessive bearing play? Check with Soft foot function (page 4-29).
6-13 Error messages ROTALIGN error messages LASER OFF Laser is either switched off, not pointing into the center of the receiver, or there is an obstruction, e.g. dustcap or dirt on the receiver lens. If laser moves out of receiver range during a rotation- al measurement, the RANGE EXTEND function may be used, depending on how far out of range the laser is (see page 4-46).
6-14 The ROTALIGN case The ROTALIGN case The ROTALIGN case has two key locks and a 3-digit combination Key: lock. Write down the key number in the boxes at left: The combination lock is set when purchased in such a way that it can be opened when its three digits read "000."...
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6-15 ROTALIGN accessories ROTALIGN accessories ROTALIGN accessories ALI 3.572 Lead-acid rechargeable block battery (MAIN BATT) (see page 6-17) ALI 3.576 110V/220V Mains adapter/charger (see page 6-17) ALI 3.581-5 ROTALIGN Receiver cable 5 m ALI 3.579 ROTALIGN Beam Deflector ALI 3.606 Receiver dust cap ALI 3.607 Laser dust cap...
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6-16 ROTALIGN accessories ROTALIGN Commander 2 ALI 3.591set ROTALIGN Commander 2 Upgrade ALI 3.591uset The ROTALIGN Commander 2 is a suite of Windows -compatible programs which includes the ROTALIGN File Commander, the ROTALIGN Horizontal Editor and the ROTALIGN Vertical Editor. Together, the programs can be used to transfer measurement files between the ROTALIGN and a PC, review and edit measurement files—which can be downloaded to the ROTALIGN, and prepare and...
6-17 ROTALIGN accessories Panel opened with Lead-acid rechargeable battery ALI 3.572 a 2.5 mm Allen key A rechargeable block battery can be used in place of the six "C" cells. (supplied) The 8-volt lead-acid battery has a capacity of 1.1 Ah (which is adequate for 9 hours of operation under normal operating condi- tions;...
6-18 ROTALIGN accessory brackets ROTALIGN accessory brackets Magnetic sliding bracket ALI 2.230I n order to accurately align two machines with each another, the position of their shafts must be measured by measuring radial displacement (such as ROTALIGN does) while the shafts are rotated. Unfortunately, some machines do not fulfill this requirement as their shafts cannot be rotated slowly for measurement.
6-19 ROTALIGN accessory brackets Before mounting the sliding bracket, the coupling or shaft should be cleaned, then lightly lubricated at the appropriate location to allow the bracket to slide around smoothly. The laser should always be mounted on the side with the highest- quality finish.
6-20 ROTALIGN accessory brackets Compact magnetic bracket ALI 2.112 set Especially when large machines are to be aligned, the coupling flange may be the most advantageous surface for mounting the ROTALIGN laser and receiver. This compact bracket uses four powerful magnets to hold the standard ROTALIGN support posts against any flat, smooth ferro- magnetic surface.
6-21 ROTALIGN accessory brackets Coupling bolt hole bracket ALI 2.106 set This magnetic bracket can serve as a useful substitute for the standard chain-type bracket when the system must be mounted on large couplings with large bolt holes. Thanks to its four powerful samarium-cobalt magnets, this bracket provides quick and sturdy mounting by straddling the bolt hole;...
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6-23 Infrared interface package ALI 4.609set Infrared interface package ALI 4.609set The ROTALIGN computer and receiver can be set up with an infrared link instead of a cable. This is useful for continuously rotating shafts, or where a cable could get caught during rotation. The infrared Recommended accessories: interface package ALI 4.609set includes: ALI 3.576...
6-24 Advanced diagnosis & correction of soft foot Advanced diagnosis & correction of soft foot Besides the two most common types of soft foot previously discussed (page 4-29)—parallel and angular soft foot—a number of other problems may cause excessive soft foot readings: If ROTALIGN measures a soft foot, but feeler gauges cannot be inserted beneath the foot, there may be rust or dirt beneath the foot: This type of "spongy"...
6-25 Advanced diagnosis & correction of soft foot Soft foot examples The following notation is used for these examples: The feet are shown oversize outside of the machine outline. ROTALIGN readings are outside the feet. Feeler gauge readings are inside the feet. Blank spaces mean the reading is not available.
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6-26 Advanced diagnosis & correction of soft foot Example 2 88 88 88 88 88 76 76 76 76 76 84 84 84 84 84 80 80 80 80 80 92 92 92 92 92 80 80 80 80 80 Identical and opposing ROTALIGN readings prompt feeler gauge examination of feet B and D.
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6-27 Advanced diagnosis & correction of soft foot Example 4 96 96 96 96 96 0 0 0 0 0 4 4 4 4 4 One foot having high ROTALIGN readings prompts feeler gauge examination of foot B. The feeler gauge readings show a clearly defined bent foot.
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6-28 Advanced diagnosis & correction of soft foot Example 6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Feeler gauges are used to examine the foot with the largest ROTALIGN reading, but no gap is found.
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6-29 Advanced diagnosis & correction of soft foot Summary When eliminating soft foot follow these steps: 1. Check all four feet of one machine with ROTALIGN. If any of the feet shows a soft foot reading over 8/100 mm (or 2 mils), proceed with step 2, otherwise go to step 5.
6-30 Sample ROTALIGN Report Sample ROTALIGN Report Here is an example of a ROTALIGN "graph ROTALIGN / V 2.00 J / ID92311491 / 0 report" (see page 3-6). The "print report" is Horizontal machine alignment 3.6.1996 17:37 identical but without =================================== the diagrams.
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6-31 Sample ROTALIGN Report ROTALIGN / V 2.00 J / ID92311491 / 0 Horizontal machine alignment 3.6.1996 17:37 =================================== ACHEMA 3.6.96 17:37 PAGE 2 =================================== **** THERM. GROWTH RIGHT MACHINE Front foot (vertical) (mm) Back foot (vertical) (mm) Front foot (horizontal) (mm) Back foot (horizontal) (mm)
6-32 Practical examples of thermal growth entries Practical examples of thermal growth entries A general description of the thermal growth function is given on the following pages. Entered values reflect the expected amount of thermal growth at the individual machine feet. Consider, for example, the following diagram of "cold"...
6-33 Practical examples of thermal growth entries Thermal growth for stationary machine If one of the machines cannot be moved during alignment, yet exhibits thermal growth, the following procedure is used: The stationary machine is first defined under the ROTALIGN menu item "Machine type"...
6-34 Practical examples of thermal growth entries Special case: parallel growth Pumps, in particular, often present the special situation in which they must be handled as stationary machines, yet exhibit thermal growth of a pure parallel nature (i.e. both front and back feet rise by the same amount as the machine warms up).
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6-35 ROTALIGN Technical Data ROTALIGN ® Technical data Laser emitter Power supply 6x 1.5 V (IEC LR 14) Size "C" Laser GaAlAs semiconductor laser (alkaline standard, Wavelength 675 nm (typical) NiCad rechargeable optional) Beam diameter 5 mm Optional: Lead-acid block battery Beam divergence <0.3 mrad rechargeable by computer...
6-36 Warranty, service and care Warranty, service and care ROTALIGN is a precision measurement instrument which should be handled as such. When not in use, it should always be stored in its protective carrying case. Warranty The ROTALIGN laser diode is guaranteed for two years. All other system components are covered by a one-year warranty.
6-38 Index A.C. power - see Power supply Cables and connections ..... 2-7,2-8,4-13 Accessories ..........6-15 Case ............6-14 Accessory brackets ........6-18 CE conformity ........1-5 chain-type bracket ......6-22 CHANGE APPLIC ......3-2,3-8 compact magnetic bracket ....6-20 CHANGE MODE ........4-20 coupling bolt hole bracket....6-21 Charger ..........
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6-39 Index EDIT (configuration) ........ 3-2 L ? R (left/right machine) ..... 4-17,4-59 EDIT (dimensions) ..4-21,4-40,5-6,5-14 LAMIBLOC ..........6-3 EDIT FILE INFO ........3-6 LANGUAGE ........... 3-2 EDIT NAME ..........3-4 Laser ............2-13 Electronic memory ......2-12 adjustment ....... 4-23 - 4-25 Emitter - see laser mounting .........
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6-40 Index Resetting computer ....... 4-15,6-11 Results "Neither measured nor target values" ..4-32 explanation of screen ..4-5,4-49 4-50 NEW (file)..........3-5 horizontal machine ....4-49 4-50 NEW MACH ....... 4-4,4-16,5-5 key ......... 2-4 2-5, 4-49,5-9 Nonsymmetrical flange shape ....5-11 vertical machine ........
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6-41 Index Specifications ......... 6-35 Speed - see RPM Warranty ..........6-36 START ..4-5,4-34,4-51,4-53,4-54,5-10,5-17 Water resistance ........1-8 START EXTEND ........4-47 Static feet ..........4-65 Status line ..........2-4 XY VIEW ........4-25, 4-43 STOP - see START ZOOM ............ 4-52 STOP EXTEND ........4-47 H ZOOM ..........
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6-42 Be sure to visit our Internet homepage for info on new products, accessories and applications! PRÜFTECHNIK Alignment www.pruftechnik.com P.O. Box 12 63 85730 Ismaning www.pruftechnik.com Tel. +49 (0)89-99616-0 Fax +49 (0)89-99616-200 eMail: info@pruftechnik.com Printed in Germany ALI 9.381.01.00.03G ROTALIGN ®...
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