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Overview:

ROTALIGN Ultra
Shaft alignment

Part 1
ROTALIGN Ultra
System operating instructions
Part 2
ROTALIGN Ultra
Shaft alignment
operating instructions

Operating Instructions

Dear Customer,
If you have any suggestions for improvement or corrections (not
only to this manual, but also to software or hardware), please
drop us a line. We would be glad to make improvements wherever
possible. We look forward to hearing from you.

Edition February 2005


Firmware version 1.20
ALI 9.846.G

PRFTECHNIK Alignment Systems


Documentation Department
Fax (+49) 89-99616-100
Email: info@pruftechnik.com

1-2
Foreword

Foreword
This manual welcomes the user to the world of laser-optical shaft
alignment with ROTALIGN Ultra, the third generation ROTALIGN
system. It deals primarily with shaft alignment of rotating equipment
mounted horizontally or vertically. This manual should always be
used in conjunction with ROTALIGN Ultra part 1 ALI 9.845.G the
system operating instructions.
ROTALIGN Ultra is evidence of our 30 years laser shaft alignment
experience, and replaces the enormously successful ROTALIGN PRO.
The system is highly fashionable, has a comprehensive set of features
and straightforward operation.
The system packages all the features available in ROTALIGN PRO
shaft alignment plus many more new ones.
The large display screen and its clear presentation of machine
graphics and corresponding menus, transform the experience of
using hand held laser alignment systems. Useful information and
time-saving steps are just one key press away.
The system handles the alignment of drive trains comprising up to 14
machines. The 'Dimensions' screen is so structured that machine and
coupling properties can be inputted directly.
The system incorporates standard deviation, a function that evaluates
the reliability of the measurement results. Quality of the alignment
result is improved using the measurement ellipse which shows the
points measured and the angle of rotation.
The measurement screen indicates whether the shown coupling
results are "from history" or are "the last measured". The measurement table and "history" have been refined.
This handbook sets out to help the instrument user work through the
instrument with the required ease. It is meant to be a quick learning
tool that hopefully should make compelling reading.
We welcome feedback so if anything is unclear, please let us know.

ROTALIGN Ultra_II 11.04

Ismaning, Germany
November 2004
PRFTECHNIK Alignment Systems

1-3
Contents

Contents
Chapter 1 Shaft alignment application ........ 1-5 to 1-34
Starting the application ...................................................................... 1-5
Starting the licence manager ......................................................... 1-5
Preparing for alignment ...................................................................... 1-7
Mounting brackets ............................................................................. 1-8
Mounting laser and receiver ............................................................... 1-9
Connecting receiver .......................................................................... 1-10
Switch computer on ......................................................................... 1-11
Set-up ..............................................................................................
Machine properties .....................................................................
Coupling properties .....................................................................
Machine dimensions ....................................................................

1-12
1-12
1-16
1-18

Laser beam adjustment .................................................................... 1-19


Taking measurements ....................................................................... 1-21
Results ............................................................................................. 1-23
Sign convention .......................................................................... 1-25
Alignment quality ........................................................................ 1-25
Aligning machines ............................................................................
Horizontal and vertical live MOVE ................................................
Shimming ....................................................................................
Lateral positioning .......................................................................

1-26
1-26
1-28
1-29

Saving and printing measurement files ............................................. 1-30


Saving files .................................................................................. 1-30
Printing reports ........................................................................... 1-32

Chapter 2 Special alignment options ........... 2-1 to 2-32


Measurement modes ..........................................................................
Multipoint measurement ...............................................................
Static measurement .......................................................................
Pass mode .....................................................................................
Dial gauge mode ...........................................................................

2-1
2-2
2-2
2-3
2-4

ROTALIGN Ultra_II 11.04

Measurement options ......................................................................... 2-8


Measurement table ....................................................................... 2-8
Showing history ............................................................................ 2-9
Identifying history labels .............................................................. 2-11
Editing raw data .......................................................................... 2-13
Extending measurement range .................................................... 2-15
Averaging ................................................................................... 2-16
Set-up options ..................................................................................
Machine type and fixation ...........................................................
Machine mounting ......................................................................
Coupling type .............................................................................

2-17
2-17
2-17
2-19

1-4
Contents

Coupling results format ...............................................................


Sign convention ..........................................................................
Coupling targets .........................................................................
Tolerances ...................................................................................
Thermal length calculator ............................................................

2-19
2-23
2-23
2-23
2-25

Soft foot .......................................................................................... 2-26


Checking and correcting soft foot conditions .............................. 2-27

Chapter 3 Special applications ...................... 3-1 to 3-21


Machine train alignment .................................................................... 3-1
Set-up ........................................................................................... 3-1
How to align machinery trains ....................................................... 3-3
Flanged machines ............................................................................... 3-6
Set-up ........................................................................................... 3-6
Measurement .............................................................................. 3-12
Results ........................................................................................ 3-13
Sign convention .......................................................................... 3-13
Alignment ................................................................................... 3-17
Suggested alignment tolerances ....................................................... 3-18
Tolerance table ................................................................................. 3-19

ROTALIGN Ultra_II 11.04

Index ................................................................................................ 3-20

1-5
Starting application

Chapter 1: Shaft alignment application


Starting the shaft alignment application
Before the application can be started, a licence code must be
entered in the licence manager.
Starting the licence manager
After switching ROTALIGN Ultra on, use the navigation keys to
highlight 'Device configuration'.

Press

to access this option.

ROTALIGN Ultra_II 11.04

Use the navigation keys to highlight 'License Manager'. Press


access 'License Manager'.

to

)
Note

1-6
Licence manager

Use the navigation keys to highlight 'Shaft Alignment'. Press


and
proceed to enter the application registration key in the editing box.

ROTALIGN Ultra_II 11.04

After successful registration, a green tick appears next to the


application and shaft alignment can be started.

1-7
Machine alignment - preparation

Machine alignment
1. Preparing for the alignment procedure
Before using the ROTALIGN Ultra shaft alignment application,
prepare the machines as described below.
Switch off the machines before commencing work, and make sure
that they cannot be started accidentally!
WARNING

a. Solid, flat foundation


A solid, rigid foundation is required to obtain correct, lasting shaft
alignment that allows long-term uninterrupted machine service.
b. Machine mobility
If the machine to be moved stands directly on the foundations, it
cannot be lowered for alignment correction. It is therefore advisable
to start with about 2 mm (80 mils) of shims beneath the feet of both
machines. Hydraulic or screw-type positioning aids are recommended for horizontal movement.
c. Rigid couplings
Rigid couplings must be loosened before measurement so that they
do not distort the alignment condition.
d. Shaft play and coupling backlash
Axial shaft play of up to 3 mm (1/8") has no adverse effect on
alignment results (but not necessarily for machine operation!).
e. Soft foot
Soft foot causes the machine to tip into a different position every
time the bolts are loosened, making proper alignment difficult or
impossible.
f. Thermal growth, alignment targets, tolerances
These values can be obtained from the individual machine specifications, and then entered into the program.
g. Measurement separation
Since ROTALIGN Ultra requires no mechanical connections (such as
cantilevered dial indicator brackets) to span over the coupling during
measurement, alignment may easily be performed over large
laser receiver separations.
Note that over very large distances the shafts and coupling may sag,
and the machines may need to be aligned to take this into account.
Refer to the machine manufacturer's specifications.

2. Check soft foot


ROTALIGN Ultra_II 11.04

Refer to section on soft foot on page 2-26.

1-8
Machine alignment - mounting brackets

3. Mount the brackets


Mount the brackets on either side of the machine coupling, and both
at the same angle.
Please note the following in order to obtain the highest possible
measurement accuracy and to avoid damage to equipment:
Ensure that the brackets fit solidly onto their mounting surfaces!

Bracket mounting procedure


To fit the compact bracket chains, refer to the diagram shown below
and follow the instructions carefully.
Anchor
peg
1

4
5
6

1. Choose the shortest support posts which will still allow the laser
beam to pass over the coupling flange. Insert the support posts into
the bracket.
2. Fasten them in place by tightening the hex screws on the sides of
the bracket frame.
3. Place the bracket on the shaft or coupling, wrap the chain around
the shaft and feed it through the other side of the bracket: if the
shaft is smaller than the width of the bracket frame, insert the
chain from the inside of the bracket as shown above ; if the shaft is
larger than the bracket width, insert the chain into the frame from
the outside.
4. Catch the chain loosely on the anchor peg.
5. Turn the bracket thumbscrew to tighten the assembly onto the
shaft.
6. Clip the loose end of the chain back onto itself.

ROTALIGN Ultra_II 11.04

CAUTION

Do not use self-constructed mounting brackets, or modify the


original bracket configuration supplied by PRFTECHNIK
Alignment (for example, do not use support posts longer than
those supplied with the bracket).

1-9
Machine alignment - mounting components

The bracket should now be tight upon the shaft. Do not push or pull
on the bracket to check, since this could loosen its mounting.
To remove the brackets, loosen the thumbscrew, then remove the
chain from its anchor peg.
The compact chain-type brackets cover most situations, but in
cramped or special cases, other types of brackets may be required.
Ask your PRFTECHNIK representative for details.

4. Mount laser and receiver


Mount the laser on the support posts of the bracket fixed on the shaft
of the left machine (usually reference machine), and the receiver on
the support posts of the bracket fixed on the shaft of the right
machine (usually moveable machine) - as viewed from normal
working position. Ensure that the yellow knobs are loosened enough
to let you slide the housing onto the support posts.
Laser
Locking knobs

Laser
Receiver
Mount just high
enough to clear
coupling
Cable clip

ROTALIGN Ultra_II 11.04

Clamp both the laser and the receiver onto the respective support
posts by tightening the yellow knobs. Ensure that the laser can pass
over the coupling and is not blocked. Fasten the receiver cable to one
of the support posts using a cable clip.

)
Note

1-10
Machine alignment - connecting receiver

Both the laser and receiver should be at the same height, as low as
possible, yet just high enough for the beam to clear the coupling
flange. They should also visually appear to be parallel to each other.
Make the final adjustments, loosening the brackets slightly if necessary, then rotating them and retightening.

5. Connect the receiver


Insert the quick fit straight-ended receiver cable plug into the eightpin socket on the top of the computer housing with the red dot at the
front.

Receiver cable

Match the double-sided arrow head on the plug to the red marking
on the socket to ensure proper plug orientation; otherwise the pins
inside the plug may be damaged.
To disconnect, grasp the ribbed collar of the plug on the receiver
cable (ALI 3.581-2) and carefully pull it out of the ROTALIGN Ultra
RS232/Sensor socket.

ROTALIGN Ultra_II 11.04

CAUTION

1-11
Machine alignment - switch computer on

6. Switch ROTALIGN Ultra on and start application


Press and hold the 'On/Off/Enter' key for approximately 5 seconds.

Select 'Shaft Alignment' using the navigation keys. Press


to access
the application. The opening template in the set-up screen below
appears.

ROTALIGN Ultra_II 11.04

The above screen will appear only if the customization option


'Resume policy' has been set to 'Resume files manually'. (See
customization - described in chapter 2 of ROTALIGN Ultra part 1,
ALI 9.845.G.)

)
Note

1-12
Machine alignment - set-up

7. Set-up
Machine information and dimensions required in set-up can be
entered in the following way:
The machine or coupling or dimension required is selected using
the navigation keys.
After the item or parameter required has been highlighted, press
to either access its properties or enter required data.
To enter or edit a dimension or name, highlight the dimension or
the name box using the navigation key and either press
to
access the editing box or enter required dimension or name
directly using the data entry keys.

Press

or

to confirm entry.

7.1 Machine properties


The set-up screen is used to enter and edit machine properties and
dimensions.
Use the navigation keys to select machine to be edited. Press
access machine properties.

to

ROTALIGN Ultra_II 11.04

To select machine type, use the navigation keys to place cursor on


'Type' and press . A drop down menu appears, and type of machine
or
.
is selected. Confirm selection by pressing

1-13
Machine alignment - set-up

Repeatedly pressing
brings you
back to the set-up screen.

Edit machine name by placing cursor on the name box and then
pressing . Use the data entry keys to to edit the machine name, and
or
.
confirm entry by pressing either

When entering names that contain


both upper and lower case characters, as well as numerals, use
to
cycle through the three options.

Press and hold down


while
observing the status indicator at the
bottom right corner of the screen.
This displays the character to be
entered.

ROTALIGN Ultra_II 11.04

1-14
Machine alignment - set-up

To enter the type of machine mounting use the navigation keys to


place the cursor on the fixation box. Press . A drop down menu
appears.

Use the upwards and downwards navigation keys to select type of


mounting. Confirm selection by pressing .

ROTALIGN Ultra_II 11.04

Depending on the type of mounting, either the position or number


needs to be edited. If the machine is mounted on feet or bearings, the
number is edited by placing cursor using the navigation keys on the
to highlight the numeral. Edit value using
fixed points box. Press
the upwards and downwards navigation keys. The digit increases by
and decreases by pressing
. Confirm value by
pressing
pressing .

1-15
Machine alignment - set-up

If however the machine is flange-mounted, the position of the flange


requires to be entered. This is done by placing cursor on the location
box and pressing . Select position from the drop down menu using
or
, and confirm selection by pressing either
or
.
either
Thermal growth values can be entered only when the type of
mounting is either machine feet or bearing or v-shaped support. To
enter thermal growth values press
while in the 'Machine type'
screen. The context menu appears.

Thermal growth values are


activated when the 'thermal
growth enabled' box is
checked.

Use either
or
to highlight 'Thermal growth'. Press
to
confirm selection. The thermal growth screen shown below appears.

ROTALIGN Ultra_II 11.04

Use the navigation keys to cycle through the feet positions and enter
values by highlighting the value box using the navigation keys and
to access the editing box or enter thermal growth
either press
value directly using the data entry keys.

1-16
Machine alignment - set-up

7.2 Coupling properties


Coupling properties are entered and edited in the same manner as for
machine properties.

while in the 'Coupling type'

Use either
or
to highlight 'Targets'. Press
to confirm
selection. The coupling targets screen that follows appears.

ROTALIGN Ultra_II 11.04

To enter coupling target values, press


screen. The context menu appears.

1-17
Machine alignment - set-up

Select coupling format using either


or
, and confirm selection
.
by pressing

Use the navigation keys to cycle through the coupling properties. To


select coupling format or enter target values, use the navigation keys
to highlight the respective box. Press
to either show the drop
down menu or access the editing box.
Coupling target values can only be entered if the 'Targets enabled'
box has been checked.

)
Note

To enter coupling target value,


highlight the value box using the
navigation keys and either press
to access the editing box or enter
required value directly using the
data entry keys. Press
or
to
confirm entry.

ROTALIGN Ultra_II 11.04

1-18
Machine alignment - set-up

ROTALIGN Ultra_II 11.04

7.3 Machine dimensions


to
After machine and coupling properties have been entered, use
return to the set-up screen. Use the navigation keys to select and
enter machine dimensions.

1-19
Machine alignment - laser adjustment

8. Laser beam adjustment


After entering all dimensions, press
the measure key. The laser
and receiver need to be adjusted so that the laser beam strikes the
receiver.
1. Remove the dust cap from the laser and use the ON/OFF switch to
turn it on if you have not already done so. Leave the receiver dust
cap on.
Do not stare into the laser beam!
WARNING

2. If the laser and receiver have been roughly positioned to each


other during mounting (see section 4), the laser beam should
strike the receiver dust cap. If the beam be so far off target that it
misses the receiver completely, hold a sheet of paper in front of
the reflector to locate the beam and readjust it onto the receiver as
follows:
3. Reposition the components until the laser beam strikes the
receiver cap:
vertically: loosen the locking knobs and adjust the height.
horizontally: loosen the bracket and turn the laser and/or
receiver brackets into line with one another.
4. Use the adjustment wheels on the laser to center the laser beam
on the receiver cap, then remove the cap.
The adjustment tube ALI 3.608 can be very helpful when misadjustment is great, especially over long separations.

Laser

1.

2, 3.

ON/OFF switch

4.

Receiver

vertical

ROTALIGN Ultra_II 11.04

horizontal

1-20
Machine alignment - laser adjustment

Center the laser beam.

ROTALIGN Ultra_II 11.04

The automatic measurement screen


is accessed from the set-up screen
, the measure key, is
when
pressed twice. This screen allows
measurement to be carried out
using continuous sweep mode or
multipoint mode or static mode.

1-21
Machine alignment - measurement

9. Taking measurements
Once the beam is centered, the display prompts the user to rotate
shafts. The standard measurement mode is the continuous sweep
method, which automatically begins measurement when the shafts
are rotated.
Other measurement modes are available. The table below gives a
guide as to which measurement mode is ideal for which measurement. In this section we describe the continuous sweep. Details on
the other modes can be found in the 'Measurement options' section in
chapter 2.

Measurement mode

Application

Continuous sweep

standard machines

Multipoint measurement

uncoupled shafts, nonrotatable shafts,


sleeve bearings, white metal bearings,
journal (radial) bearings

Static measurement

vertical machines (four feet or flange


mounted)

Pass mode

uncoupled shafts, nonrotatable shafts

Dial gauge

verifying measurements taken using


dial indicators

Rotate the shafts a full turn, or as far as possible.

ROTALIGN Ultra_II 11.04

1-22
Machine alignment - measurement

Press
to access the context menu so that measuring can be
finished and data collected in order to display results.
Use the navigation keys to highlight 'Stop'. Press
to stop measurement and display coupling
results. This step is used in the
continuous sweep mode only.

On pressing

, the following screen appears.

Results can be obtained after a


minimum rotation of 60.

Coupling results

ROTALIGN Ultra_II 11.04

Standard deviation (SD) measures


the spread of the data about the
mean value. The lower the standard
deviation of a set of measurement,
the higher the accuracy of the
shown result.

1-23
Machine alignment - results

10. Results
Once measurement is completed, press

to view alignment results.

Coupling values

Feet position
In this example, the left machine
was defined during set-up as
static.

The above display shows the measured alignment condition along


with numerical values for the actual machine feet positions.

If however both machines are movable, any two desired feet pair
may be designated as static.

)
Note

To designate any pair of feet


fixed, place the yellow vertical
line on the feet pair using
or
. the navigation buttons.
to fix the selected pair
Press
of feet. The feet position is
highlighted black. To unfix any
pair of feet, place the vertical
line on the static pair of feet pair
or
and then press
using
.

ROTALIGN Ultra_II 11.04

Static feet pair


Unfixed feet pair

1-24
Machine alignment - measurement

The context menu shown opposite


appears when
is pressed from
the results screen.

The context menu items are scrolled using either


or
.
Selection is confirmed by pressing
. The screen below appears
when the item 'Options' is selected.
Tolerance envelopes can be activated or deactivated from this screen.
The viewing option can also be set
from this screen.

ROTALIGN Ultra_II 11.04

The context menu is also used to


select the desired depiction.

1-25
Machine alignment - results

10.1 Sign convention


The following sign convention is used in the evaluation of alignment
results.
With left machine stationary, gap is positive when open at top or side
away from viewer. The viewer is considered to be standing in front of
the machines as they appear on the display.
Both vertical and horizontal results show the foot position relative to
the stationary machine centerline. Positive values indicate that
machine foot is upwards or away from viewer. Negative values
indicate that machine is downwards or towards the viewer.
10.2 Alignment quality
The 'smiley' symbol by the coupling results indicates the degree to
which the measured alignment condition meets tolerances. The
smiley face appears only when tolerances are have been enabled (see
section 7.2).

Excellent

Acceptable

Out of tolerance

If all results lie within tolerance, no alignment corrections are


necessary.

)
Note

ROTALIGN Ultra_II 11.04

1-26
Machine alignment - live MOVE

11. Align machine


To align your machine you need to move it vertically by shimming
the feet, and horizontally by shifting it sideways. You could do these
operations in either order or simultaneously.
11.1 Shim first
We recommend shimming first, unless the horizontal move is
significantly larger than the shimming corrections.

)
Note

If the required horizontal correction is large, then move horizontally first. In this case the feet will move onto a different part of the
foundation, and you may need to recheck soft foot before proceeding.

11.2a Horizontal and vertical live MOVE


The alignment corrections involving shimming and the lateral positioning of the machines can be followed in a real-time interactive
. The context menu
display. From the results screen, press
appears.
Use
or
to highlight 'Move'
and then press
.

ROTALIGN Ultra_II 11.04

Confirm selection by pressing

1-27
Machine alignment - live MOVE

If the laser beam is centered proceed to carry out live horizontal and
vertical MOVE.

If however the laser beam is not centered, use the 'XY view' that
appears to center the laser and then press
to go back to the
results screen to proceed with live MOVE.

)
Note

ROTALIGN Ultra_II 11.04

1-28
Machine alignment - live MOVE

11.2b Shimming
i) Prepare the machines for shimming by ensuring the following:
The foot bolts are clean, intact & removable.
Soft foot has been eliminated.
The feet have enough shims under them should lowering the
machine be necessary.
Good quality shims such as LAMIBLOC or PERMABLOC are
available.
ii) Loosen foot bolts while avoiding to move the machine horizontally. If any foot comes off the ground when loosened, suspect soft
foot.
iii)Use the vertical foot correction values to shim BOTH front and
back feet as required. Positive feet values indicate that shims
should be removed, while negative feet values suggest addition of
shims.

ROTALIGN Ultra_II 11.04

iv)Retighten and remeasure to verify shimming results and determine the exact alignment condition.

1-29
Machine alignment - live MOVE

11.2c Lateral positioning


i) With foot bolts loosened, move machine feet keeping an eye on
the smiley on the display screen.
ii) Note the following sign convention - Positive feet values indicate
that the machine feet should be removed towards viewer, while
negative feet values suggest the moving of machine feet away
from viewer.

Do NOT attempt to move the machine using heavy sledgehammer


blows. This can cause bearing damage, and also produce inaccurate MOVE results. Jack bolts on the feet or other mechanical or
hydraulic devices are recommended for moving machines.
iii)Tighten anchor bolts and recheck alignment by taking another set
of measurements and viewing results. If they are in tolerance, then
the machines are aligned.

CAUTION

ROTALIGN Ultra_II 11.04

1-30
Machine alignment - saving and printing

12. Saving and printing measurement files


Before switching off the instrument, dimensions, measurements,
results and all settings can be saved for analysis, future use or record
purposes in the instrument's non-volatile memory.
Files can be set up and then saved or measurements carried out and
then the results be saved.
12.1 To save a file
a) Measurement files can be saved using the global menu. To access
. The context menu appears. Select
the global menu, press
or
.
'Menu' using either

b) Press . The global menu appears. Select 'Save' using either


or
.

ROTALIGN Ultra_II 11.04

The global menu seen opposite


appears when the customization
option global menu style is set for
'Use title bar global menu'. The
menu bar is navigated using either
or . All the menu bar items are
cascading and their respective items
or
.
are accessed using
Items with other cascading menus
are indicated with bold right
arrows (as in 'File' menu item 'Open
recent).

1-31
Machine alignment - saving and printing

The global menu seen opposite


appears when the customization
option global menu style is set for
'Use full screen global menu'. The
menu items are navigated using the
navigation keys or shortcut numbers. For example selecting
followed by
when in the screen
opposite selects the 'save file'
option.

c) Press

. The 'Save document as' screen appears.

d) Press . Select location to save file using either


or
, and
then press . And proceed to enter the file name using the data
or .
entry keys. Confirm file name by pressing either

ROTALIGN Ultra_II 11.04

1-32
Machine alignment - saving and printing

12.2 To print report after measurement


Measurement files can be printed either direct from the results screen
or from the shaft alignment set-up screen.
a) Connect the ROTALIGN Ultra computer to your printer using the
ROTALIGN Ultra USB/peripheral devices cable ALI 4.503. Depending on your printer interface, you may require an A to B USB
cable. Most printers are delivered with this USB cable which is also
readily available from most electronic goods dealers.

ROTALIGN Ultra
USB/peripheral
devices cable
ALI 4.503

A to B USB cable

c) Press
. The context menu appears (as seen on the next screen).
or
.
Select 'Report' using either

ROTALIGN Ultra_II 11.04

b) Press
repeatedly until the machine configuration overview
appears on the display screen.

1-33
Machine alignment - saving and printing

c) Press either
required.

or

to select the language and type of report


Use either or to switch between the two panes.
Use either
or
to select the
required report format and language. Item selected from any pane
appears as grey when the opposite
pane is highlighted.

d) Press

to print report in required format and language.


If no report is printed check the
printer set-up described in the
System operating instructions
ALI 9.845.G.

ROTALIGN Ultra_II 11.04

1-34
Machine alignment - completion

13. Alignment completion


After completion of an alignment measurement or job, press
to
switch ROTALIGN Ultra off . If the measurement file has not been
saved, the following query appears:
'Do you really want to turn off the system?'
Selecting 'Yes' to turn off the system prompts the following question:
'Do you want to save changes in file?'
Save file if required for record and analysis. If it is not required,
selecting 'No' turns off the system.
After ROTALIGN Ultra has been switched off, disconnect the
transducer cable from the system.
Switch the laser off and replace both laser and receiver dust caps.
Remove the components from the shafts and store them in the
case.
Replace guards before you switch the machine back on.

ROTALIGN Ultra_II 11.04

WARNING

2-1
Measurement modes

Chapter 2: Special alignment options


2.1 Measurement modes
In addition to the standard 'continuous sweep mode', ROTALIGN
Ultra also offers multipoint, pass, static (0369) and dial gauge
measurement modes.
The measurement modes can be accessed via the measurement
screen. After set-up, press
. The measurement screen appears.
While on this screen, press
. The context menu appears.
Use
or
to highlight 'Mode'
.
and then press

Confirm selection by pressing


screen appears.

. The measurement mode selection

ROTALIGN Ultra_II 11.04

Use the navigation keys to select the required measure mode.


Confirm selection by pressing .

2-2
Measurement modes

Multipoint measurement
This mode is used to measure shafts which are either difficult to turn
continuously or allow measurement only in certain rotational positions.
The method can also be used to measure uncoupled shafts, nonrotatable shafts, sleeve bearings, white metal bearings and journal (radial)
bearings.
to
After centering the laser beam as described in chapter 3, press
take the first measurement point. Rotate shafts in their normal
direction of operation from one measurement position to the next.
Press
take measurement. Measurements must be taken in at least
three positions over at least 60 of rotation, but more measurements
over a wider angle is recommended.
Coupling results are displayed after
a minimum of three measurement
points have been taken. The
standard deviation (SD) appears
after 4 or more readings.

After finishing measurement, press

to view results.

Static measurement
This measurement mode is used for uncoupled shafts, nonrotatable
shafts and vertical foot-mounted or flange-mounted machines.

Rotate shaft to the next measurement position. Use the navigation


keys to change the orientation of the laser unit on the display screen
to correspond to the shaft position.

)
Note

Take next measurement point by pressing

If shaft rotation restrictions hinder the taking of measurement at


particular shaft positions bypass these using the navigation keys.

ROTALIGN Ultra_II 11.04

After centering the laser beam as described in chapter 3, turn the


shaft to any of the eight 45 positions (i.e. 12.00, 1.30, 3.00, 4.30,
6.00, 7.30, 9.00 or 10.30 o'clock position viewed from receiver
towards laser). Position shaft as accurately as possible using either an
to take the
external inclinometer, spirit level or protractor. Press
first measurement point.

2-3
Measurement modes

The navigation keys are used to


position the laser unit on the
display screen to correspond to the
actual shaft position.

Measurements must be taken in at least three positions over 90, but


more measurements over a wider angle is recommended. After
to view results.
finishing measurement, press
Pass mode
Uncoupled or nonrotatable shafts (one or both) can best be measured in 'pass' mode, where the laser is rotated past the receiver in
several different rotational positions. The laser and receiver can be
mounted in a variety of ways depending on the alignment situation.

Uncoupled shafts:
Mount sensors
using chain-type brackets

Nonrotatable shaft(s):
Mount sensors using magnetic
sliding bracket (ALI 2.230).

ROTALIGN Ultra_II 11.04

After centering the laser beam as described in chapter 3, press


to
take the first measurement point, then rotate the receiver to the next
measurement point.
Rotate the laser slowly past the receiver. When the receiver takes a
measurement at its current position, the green LED on the front of its
housing lights for about one second.

Magnetic sliding
bracket ALI 2.230

2-4
Measurement modes

Cover the laser aperture (i.e. with one hand) and rotate the receiver
to the next measurement position; repeat the procedure to take
measurements in at least three positions over at least 60 of rotation,
but more measurements over a wider angle is recommended.

Laser beam
6

Receiver
4

Adjust laser beam


Laser 'passes' receiver
(measurement)

After pressing
to start measurement, the two circles are dotted
red.

After finishing measurement, press

. The context menu appears.

ROTALIGN Ultra_II 11.04

Use
or
to highlight 'Stop'
and then press
.

2-5
Measurement modes

On confirming selection by pressing


displayed.

Press

, the coupling results are

to view foot results.

Dial gauge mode


This mode is used to convert dial gauge readings into ROTALIGN
Ultra values, hence verifying calculations and comparing measurement results with those obtained using ROTALIGN Ultra.
. The measurement screen appears. From the measurea. Press
. The context menu appears. Use
or
ment screen press
to select 'Mode'. Press
to confirm selection. From the
measurement mode screen that appears, use the navigation keys
to confirm selection.
to select 'Dial gauge mode'. Press
Use
or
to highlight 'Gauge
.
set-up' and then press

ROTALIGN Ultra_II 11.04

b. Press
above.

and use

or

to select 'Gauge set-up' as shown

2-6
Measurement modes

c. Press

to confirm selection.

In this method, enter the height of


the axial gauge from the shaft
center.

Here, we enter distance from the


radial gauge to the coupling center.

Enter radial and axial sag values.

f. To view ROTALIGN Ultra gap and offset coupling values, press


, and from the context menu that appears, use
or
to
select 'Stop' as shown overleaf.

ROTALIGN Ultra_II 11.04

d. Use the navigation keys to select the desired dial gauge method.
to confirm selection. Proceed to enter required values
Press
using the data entry keys.
e. After entering the required dimensions and the amount of bracket
to return to the dial gauge measurement screen to
sag, press
enter the dial gauge values. Press
to access the value entry
boxes.

2-7
Measurement modes

g. Press

to view the coupling results.

h. Press

to view foot results.


Pressing
reveals the results
screen showing feet positions if the
dimensions have already been
entered. If dimensions are missing,
the set-up screen prompting dimensions appears.

ROTALIGN Ultra_II 11.04

2-8
Measurement options

2.2 Measurement options


Measurement table
All measurements taken on the current set of machines are registered
in a measurement table which can be viewed directly following
measurement.
The measurement table is accessed through the 'Measurement'
while in measurement. Use
or
to select
screen. Press
to view the
'Table' from the context menu that appears. Press
measurement table.

The contents of the measurement table from left to right include the
measurement position, measurement mode, vertical and horizontal
coupling values, standard deviation, distance from coupling center to
receiver, and the date and time when a particular measurement was
taken.
Measurement points, alignment records, and the coupling to receiver
distance can be edited from the measurement table screen. To access
while in the 'Measurement table' screen. Use
these items, press
or
to select item to be edited or measurement to be deleted
to edit selected item.
from the context menu that appears. Press

ROTALIGN Ultra_II 11.04

The measurement table is scrolled


downwards, upwards and sideways
using the navigation keys.

2-9
Measurement options

Up to 50 measurements can be stored in a measurement table.


Changes made in the set-up screen affect only later results, not earlier
ones.
Multiple measurement sets can be averaged to achieve more representative results. This feature is particularly useful for uncoupled
shafts or when bearing play is considerable. To calculate this
average, proceed as follows:
or
to highlight a measurement for inclusion in the
1. Use
average.
to select the measurement. A check mark appears next to
2. Press
the measurement position indicating that the measurement has
been included in calculating the average.
3. Repeat steps 1 and 2 for all other measurements to be included.
To remove a measurement from the average calculation, highlight the measurement using the navigation bars and press .
The check mark next to the measurement position disappears
indicating that the measurement is not include in calculating the
average.

)
Note

Showing history
The measurement table can be configured to display the job record.
Individual measurements are labelled as appropriate (e.g. 'as found',
'after soft foot' and 'after alignment'). To configure the measurement
table proceed as described below.
a) After taking (a) measurement(s) and accessing the measurement
or
to
table as described under 'Measurement table', use
highlight measurement(s) to be included in the averaging. Confirm selection by pressing .

The check marks denote the readings that have been selected and
hence included in the averaging.

ROTALIGN Ultra_II 11.04

2-10
Measurement options

b) With the measurement highlighted and check-marked, press


.
or
to select 'Add label'.
The context menu appears. Use

c) Press

to confirm selection. The screen below appears.

ROTALIGN Ultra_II 11.04

d) Use
or
to select an appropriate label from the predefined
to confirm selection. The measurement history table
list. Press
with the selected label appears as shown opposite.

2-11
Measurement options

The check-marked readings have


been included in the 'As found'
label.

Identifying history labels


To find out how many different labels have been assigned in
measurement history table, proceed as described below.
a) Access the measurement table as described under 'Measurement
table'.

. The context menu appears. Use


b) Press
'History labels'. See illustration overleaf.

or

to select

ROTALIGN Ultra_II 11.04

2-12
Measurement options

to confirm selection. The screen below appears.

c) To view measurement(s) under the selected label, press

ROTALIGN Ultra_II 11.04

Press

2-13
Measurement options

Edit raw data


To improve the quality of the alignment results, it may be necessary
to edit registered measurement data that deviates severely from
other measurements taken.
After completion of measurement, press
screen below appears.

Use
or
ellipse points.

followed by

to highlight 'Edit points'. Press

. The

to view and edit

The After pressing


to start
measurement, the two circles are
dotted red.

ROTALIGN Ultra_II 12.04

Any measurement point that deviates severely from the other values
can be deactivated from the measurement set.
Use
to select the measurement point to be deactivated. Any
selected point can be deactivated by pressing . Deactivated points
appear as unshaded circles.

2-14
Measurement options

The 'Edit raw data' context menu has the items 'Ellipse view mode',
'Toggle point', 'Max point' and 'Sensor on/off'.
The 'view mode' allows raw data to be examined from three different
views. The three views are: ellipse and corresponding points, plane
points and broken ellipse. The desired view is selected from the
. In the normal ellipse view, the width of the
context menu using
ellipse along the X axis gives an indication of shaft angularity, and its
height (on the Y axis) indicates shaft offset. When shafts are perfectly
aligned, the ellipse is reduced to a single point.
'Toggle point' is used to deactivate any selected measurement point.
or
to highlight 'Toggle point', and then press
to
Use
deactivate the selected point. This point can be reactivated by the
same procedure. The 'deactivated' measurement position can be
remeasured in the 'multipoint', 'pass' and 'static' measurement modes.
If several 'active' points result for the same position, they will be
averaged together.
'Max point' is used to highlight the measurement point with the
maximum deviation from the calculated ellipse.

ROTALIGN Ultra_II 12.04

Selecting 'Sensor on' shows the current beam position on the screen.
With this function, repeatability can be checked by following the path
of the beam as the shafts are turned through the measurement
positions again. The beam should move along the curve of the ellipse
without appreciable deviation.

2-15
Measurement options

Extending the measurement range


Gross misalignment of shafts or small angular misalignment over
large distances can cause the laser beam to miss the detector surface
during measurement. When this happens, 'Laser End' appears on the
display screen and the instrument's 'extend' function can be used.
1. When measuring and 'Laser End' message appears, rotate the
shafts backwards until the laser beam reenters the measurement
range. The message 'Laser OK' reappears on the display. Press .
The context menu as seen below appears.

'Laser END' is displayed when the


reflected beam misses the detector.

The 'extend' option is available only


in 'multipoint' and 'static' measurement modes.

2. Use
or
to highlight 'Extend', and then press
. The
program interrupts measurement and switches to 'XY View'. The
current beam position is automatically taken as the starting point
for range extension.

ROTALIGN Ultra_II 12.04

3. Readjust the beam into the target circles using the yellow laser
emitter adjustment wheels and then press .

2-16
Measurement options

The adjusted beam position is taken as the end point of displacement.


4. Continue measurement as before, rotating the shafts and pressing
the 'Take Point' softkey at the desired positions.
The program includes the displacement of beam readjustment in
its alignment calculations.
Averaging
In certain industrial conditions, it may be necessary to increase the
number of measurements to be averaged when taking readings to
attain the desired accuracy. Particular cases include plants with
increased machinery vibration. An increased averaging also improves
the accuracy when measuring sleeve bearings, white metal bearings
and journal bearings.
The number of individual readings which are averaged together to
form one measurement is selected from either the measurement
screen (for multipoint and static measurement modes) or via the XY
view screen (for continuous sweep and pass measurement modes).

If averaging is set via the XY view, press


from the corresponding
or
to highlight 'XY view'.
measurement screen and then use
to confirm selection. The XY view screen appears with the
Press
and use
or
to select
averaging box highlighted. Press
averaging value from the drop down menu and confirm value by
or .
pressing either

ROTALIGN Ultra_II 12.04

When setting the average from the measurement screen, press


and use
or
to highlight 'Averaging'. Use
or
to select
averaging value and confirm value by pressing .

2-17
Set-up options

2.3 Set-up options


Machine type and fixation
ROTALIGN Ultra provides the user with the opportunity to designate
the type and fixation for both left and right machines.
Use
to highlight machine item
boxes. Press
to either check
selected item box or prompt the
coresponding drop down menu.

ROTALIGN Ultra_II 12.04

Machine mounting
Detailed machine mounting can be specified in set-up.
In the set-up screen that follows, machine mounting has been defined
as 6 feet (3 pairs of feet), has a V-foundation and is moveable.

2-18
Set-up options

For machines with V-shaped supports, the angle between support


surfaces and foundation must be entered in order to calculate
corrections.

ROTALIGN Ultra_II 12.04

The respective angles are entered as follows:


to highlight either of the
From the dimension screen, use
support angle boxes (left side or right side). Note that the default
angle is 45, and a 0 angle indicates that the machine feet are
parallel to the foundation, while a 90 angle indicates that the feet
are perpendicular to the foundation.

2-19
Set-up options

Use the data entry keys to enter the support angle for the selected
or .
feet position, confirming entry by pressing either
and support angle as described
Select next position using
above.
All alignment corrections are achieved solely by inserting and
removing the proper combination of shims; corrections are indicated
for each individual machine foot to yield the required horizontal and
vertical displacement for the machine upon angled supports.
These corrections correspond to the values in the results screen as
shown below.
The vertical corrective values for
each foot are shown below.

Coupling type
The following coupling types are available for selection:
Short flex These couplings feature fitted transmission elements
with play (such as teeth, claws or bolts) or elastic connecting
elements like rubber 'tires' or springs.
Single plane The coupling halves are bolted directly together.
Loosen the bolts before taking measurements, since they would
otherwise distort the true alignment condition.
Spacer shaft: When the coupling halves are joined by a spacer
element, its length must be entered.
Cardan shaft: Just as with regular spacer shafts, the shaft length
(between coupling planes) must be entered.
ROTALIGN Ultra_II 12.04

Coupling results format


This parameter allows the desired display format to be selected for
depicting the coupling alignment condition. This allows direct
comparison with the manufacturer's alignment tolerances. The proper format setting depends upon the coupling type used.

0.74 mm

0.26 mm

-0.38 mm

-0.81 mm

2-20
Set-up options

Shaft angle and offset at the


coupling plane

Gap width at edge of coupling and


shaft centerline offset

ROTALIGN Ultra_II 12.04

Shaft angle

2-21
Set-up options

Gap width at edge of coupling

Shaft offset at left (B) and right (A)


coupling faces

Angle of shafts to spacer shaft


centerline

ROTALIGN Ultra_II 12.04

2-22
Set-up options

Gap at edge of left coupling (A) and


right coupling (B) of spacer shaft

A
B

ROTALIGN Ultra_II 12.04

Only angularity is of concern with


cardan shafts.

2-23
Set-up options

Sign convention
Vertical alignment plane:
Offset is positive when the right shaft centerline is higher than the
left centerline.
Gap and angularity are positive when the coupling opens toward
the top.
Horizontal alignment plane:
Offset is positive when the right axis is further away from the
viewer than the left axis.
Gap and angularity are positive when the coupling opens away
from the viewer.
Coupling targets
The position of machines at rest can be considerably different than
that during operation (e.g. due to thermal growth or load-related
displacements). This effect can be compensated through use of
alignment target values for the coupling, which allow precise
'misalignment' when the machines are at rest so that they will be in
proper alignment position during operation.
Alignment target values may be found in the machine documentation
or upon request from the manufacturer.
The coupling type determines the targets to be entered. These values
are entered as described in Chapter 1 section 7.2 - 'Coupling
properties'.

Tolerances
Alignment quality is evaluated through comparison with tolerances
based upon entered machine dimensions and RPM.
The tolerance ranges are compiled as tables according to coupling
type and diameter as well as RPM. When the coupling type is spacer,
the tolerance table values are determined by the length of the spacer
shaft and the RPM. (See suggested shaft alignment tolerances at the
end of chapter 3.)
In ROTALIGN Ultra the 'live' tolerance function can be activated or
deactivated from either the coupling properties window or the
tolerances window. When the function is checked active, the alignment quality is indicated with the 'smiley' symbol.

ROTALIGN Ultra_II 12.04

Tolerance tables are viewed as follows:


Access coupling properties as described in chapter 1 section 7.2 'Coupling properties'.
. The context menu appears. Use
or
to select
Press
'Tolerance'.

2-24
Set-up options

Alignment tolerances are


divided into two quality ranges
- 'acceptable' values are
relatively generous and intended for noncritical machines and
RPM ranges; 'excellent' values
are intended for machines and
RPM ranges that require
especially accurate shaft
alignment.

Press
to confirm selection. The tolerance table screen below
appears.

The tolerance table drop-down


menu shows all tolerances
available for the coupling type
selected.

The RPM can be edited by


highlighting the value and then
entering required value directly
using the data entry keys.
Confirm entry by pressing
or
.
either

Note

ROTALIGN Ultra_II 12.04

The given alignment tolerances are based upon standard industry


norms and must not be exceeded, and they are to be used only if
existing in-house standards or the machine or coupling manufacturer has not given any binding values.

2-25
Set-up options

Thermal length calculator


Machine conditions change from the time the machine is off line to
when it is running under normal operating conditions. Some of these
changes are due to process forces (e.g. fluid pressures, airflow). The
most notable of these changes is the change in the temperature of the
machine bearings and supports. This is called the machines thermal
growth.
ROTALIGN Ultra may be used to calculate thermal growth compensation if no other values are available. Thermal growth is calculated
from the material characteristics, expected temperature difference
and the height of the shaft centerline.
Thermal growth is calculated as follows:
or
to highlight machine whose
From machine set-up, use
thermal growth requires calculating.
to access the machine properties screen.
Press
Press
. The context menu appears. Use
or
to select
'Thermal growth'.
Press . The thermal growth screen appears.
Press
. The context menu appears. Use
or
to select
'Thermal calculator'.
to access the thermal calculator screen.
Press
Proceed to select type of material using the drop-down menu,
enter the difference to ambient temperature, and the distance
from machine base to the shaft centerline.
In the example opposite, the motor
material is cast iron, the temperature difference is 90 C and the
distance from the bottom of the
motor feet to the shaft centerline is
70 cm. This gives a growth of 0.67
mm.

ROTALIGN Ultra_II 12.04

2-26
Soft foot

4.5 Soft foot


SOFT FOOT is the condition in which 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:

Non-coplanar machine mounting surfaces,


Deformed machine frame or feet,
External forces e.g. from connecting pipe or bracket,
Improper shimming or soiled machine feet.
Too many shims under a machine foot (a maximum of 3 should be
used)

The consequences of forcibly tightening down the feet are deformed


machine frames, bent shafts and distorted bearings. This leads to
high vibration and premature failure.

Parallel soft foot


One or more feet are too short
or too long. This usually results
in the machine rocking on the
longer feet. This is corrected by
placing shim under ONE of the
short feet.

Angular soft foot


The base of the foot is at an angle
to its foundation and they are only
partly in contact. In this case,
suspect foot is checked with a
feeler gauge and corrected by
building a custom 'shim wedge' or
machining the underside of the
foot.

ROTALIGN Ultra_II 12.04

Soft foot should be checked before aligning the shafts, and this can be
done quickly and conveniently with the aid of the ROTALIGN Ultra
soft foot function. With the laser and receiver mounted on the shaft
in the usual way, the system is able to sense any machine movement
when the machine bolts are loosened individually. By entering the
machine dimensions, the computer is able to calculate, from shaft
movement, by how much each foot has moved as it is loosened.

2-27
Soft foot

Once foot movements have been established, the results are interpreted and translated into shim thicknesses to be placed under the
feet. How straightforward this is, depends on the type of soft foot
present.
Checking and correcting soft foot conditions
The three main types are parallel soft foot, angular soft foot, and
induced soft foot. There are instances where the soft foot is a
combination of two or more types. Checking for soft foot is part of
machine and job preparation.
The machine(s) to be measured should be treated first as normal
four-feet machines. For six-feet machines, measure the front and
rear feet first, then the middle and rear feet in a separate set of
readings.

The measurement procedure


1. Mount the laser and the receiver in the normal way, and then
switch on the laser. Adjust the beam onto center of the receiver
dust cap.
2. Remove the receiver dust cap.
3. Press . The context menu appears. Use / to highlight .

ROTALIGN Ultra_II 01.05

4. Press
to confirm selection. If a message appears stating that soft
foot measurement cannot be performed on the indicated machine,
to scroll to the next machine. If the laser is centered the
press
following screen appears.

)
Note

2-28
Soft foot

5. Press
to continue with soft foot measurement. If however, the
laser beam is not centered, press . The context bar appears. Use
or
to highlight 'XY view'.

to access the XY view screen.

ROTALIGN Ultra_II 01.05

6. Press

2-29
Soft foot

6. Use the adjustment thumbwheels to center the laser beam. Use


the top thumbwheel to move the beam up/down. The side
thumbwheel is used to move the beam sideways.

7. After centering the laser beam, press


to return to the soft foot
screen. Press
to proceed with measurement.
If machine dimensions have not
prompts
been entered, pressing
this action.

ROTALIGN Ultra_II 01.05

8. With foot to be measured highlighted, press . A spanner symbol


appears on the screen. Loosen the corresponding foot bolt. When
the shown value no longer rises, press .

2-30
Soft foot

9. Tighten the bolt. After tightening the bolt, press

. The spanner

symbol disappears and next foot to measured is selected using

Repeat steps 8 and 9 for each machine foot.


In this example, soft foot has been
detected and must be eliminated
before proceeding with determining the alignment condition of the
machines.

ROTALIGN Ultra_II 01.05

10. To correct soft foot, press


. The context menu appears. Use
or
to highlight 'Diagnose'. ROTALIGN Ultra presents the
user with concise instructions on how to eliminate the prevailing
soft foot.

2-31
Soft foot

11. Press

to proceed with diagnosis.


In the diagnosis opposite, feeler
gauge maesurements are required.

12. Press
to proceed with further diagnosis. The context menu
appears. Use
or
to highlight 'Enter gaps'.

ROTALIGN Ultra_II 01.05

2-32
Soft foot

13. Press
to enter feeler gauge readings. Use the data entry keys
to enter the measured feeler gauge values. After entering all four
values of the foot with the largest soft reading, press .

14. To correct the soft foot present, press


. The context menu
appears. Use
or
to highlight 'Diagnose'. Confirm
selection by pressing .

to scroll through the


eliminate the diagnosed soft foot. Use
on-screen diagnosis. After correcting the soft foot, continue with
the alignment of the machines.

ROTALIGN Ultra_II 01.05

15. ROTALIGN Ultra provides a precise description of how to

3-1
Machine train

Chapter 3: Special applications


This chapter deals with alignment of machines that require use of
special procedures rather than those for the standard horizontal
alignment. These special applications include:
Machine trains (groups of up to 14 machines coupled together)
Cardan drive machines
Flanged machines (mounted vertically or horizontally)

5.1 Machine train alignment


Set-up
a. After starting the alignment application, either select a suitable
template or configure the machines as appropriate.
while in the set-up screen.
b. To select a suitable template, press
The context menu appears.
c. Use

to select 'File'/'New'.

d. Press . The open template screen appears. Use


select required template.

or

to
After highlighting the required
template, confirm selection by
pressing
.

ROTALIGN Ultra_III 01.05

3-2
Machine train

e. Machine trains can also be configured from the set-up screen.


. The context menu appears. Use
or
to highlight
Press
'Add left' or 'Add right' depending on which end a machine is to be
added.
After highlighting the required
train end, confirm selection by
pressing
.

e. After either selecting an appropriate template or configuring the


machine train, proceed to define the machines and enter the
corresponding dimensions as detailed in chapter 1.

ROTALIGN Ultra_III 01.05

Machine elements in view are


highlighted.

3-3
Machine train

How to align machinery trains


The following step-by-step approach is recommended for multielement trains.
a. Measure alignment at each coupling
b. Display results and optimize corrections (by defining 'stationary'
machine feet)
c. Align two machines (remount sensors if necessary)
d. Check alignment results
e. Align the next two machines and repeat alignment check
f. Repeat step (e) until all machines have been aligned.
Measurement
to zoom out the machine train.
a. While in the set-up screen, use
Pressing the key repeatedly will zoom out until the entire machine
train fills the display screen.
To view any respective part of the
train closely, highlight the section
either or and then zoom in by
pressing
.

ROTALIGN Ultra_III 01.05

b. Use either
or
to select the machine coupling to be aligned
first.
c. Ensure the laser is mounted on the machine shown on the left side
in the screen diagram.
d. Remove the dust cap from the laser and switch it on. Leave the
receiver dust cap on.
the measure key and adjust the beam onto the receiver
e. Press
(see chapter 1).
f. Procede to carry out measurent as described in chapter 1,
observing the requirements for valid measurement - shafts must
be turned by at least 60, a minimum of 3 measurement points to
be taken.
to stop measurement.
g. Press
If the measurement mode used is not continuous sweep, measureand then highlighting 'Stop', and
ment is stopped by pressing
confirming selection by pressing .

)
Note

3-4
Machine train

h. Switch the laser off and mount the laser and receiver around the
next coupling.
i. Press .
j. Use
to zoom out the machine train.
k. Use either or to proceed to the next coupling.
l. Repeat the measurement procedure (step c through h) until
measurements have been taken around all couplings.
Evaluating results
a. Press
to view the alignment results at the individual couplings.

Highlights coupling
being viewed.

c. Press

to view the alignment results at the next coupling.

or

ROTALIGN Ultra_III 01.05

b. To view the results at the next coupling, press


and use
to highlight the direction arrow to the next coupling.

3-5
Machine train

d. To view the alignment results of the entire machine train, press


to zoom out the train.

ROTALIGN Ultra_III 01.05

3-6
Flanged machines

5.2 Flanged machines


The diagram below shows a typical vertical machine arrangemt with
one machine mounted on top of the other using a bolt flange.

Flange-mounted machines can be situated vertically or horizontally.


In either case, alignment corrections are made directly at the flange.
Angularity is corrected by inserting or removing shims between the
flanges. ROTALIGN Ultra calculates the shimming thickness for each
flange bolt. Offset is corrected by positioning the flange laterally.

1. Marking measurement positions


a. Mark a reference position on the coupling housing close to the
shaft and in line with one of the pillars or bolts. Likewise, mark a
starting point on the shaft.
b. Measure the circumference of the shaft and divide by eight.
c. Use this distance to make seven more evenly-spaced marks on the
shaft beginning at your chosen start point. Number the points
counterclockwise as seen from reflector to transducer, beginning
with 0 first, followed by 1:30, 3:00,4:30, 6:00, 7:30, 9:00 and
10:30.

ROTALIGN Ultra_III 01.05

Set-up
The laser and receiver are mounted on either side of the coupling as
for horizontal machines, with the laser on the shaft of the machine
designated stationary. The electronic inclinometer cannot determine
the rotation angle of vertical shafts; therefore measurements must be
taken on vertical machines using static measurement mode. The
eight 45 measurement positions used with this procedure must be
marked accordingly on the machine.

3-7
Flanged machines

For circular housings, measure the circumference of the coupling


housing and divide by eight. Use this distance to make eight
evenly-spaced marks on the housing beginning at your chosen
start point. Number the points clockwise looking down onto the
shaft with 0 as the first, followed by 1:30, 3:00,4:30, 6:00, 7:30,
9:00 and 10:30.

0
1:30 3

4:30
5

2. Set-up
a. Mount the laser and receiver on either side of the coupling,
ensuring that they are aligned exactly with the 0 or reference
mark.
b. Connect the receiver to ROTALIGN Ultra and switch on the
device.
c. Start the shaft alignment application. When the opening set-up
. The context menu as seen below
screen appears, press
or
to highlight 'Menu'.
appears. Use

ROTALIGN Ultra_III 01.05

d. Press

to access the global index.

3-8
Flanged machines

The train orientation screen can


also be accessed by selecting the
data entry keys '2' followed by '6'.

e. Use
to select 'Machine properties'/'Train settings'. Confirm
selection by pressing . The train orientation screen appears.

ROTALIGN Ultra_III 01.05

f. Use
to select 'Vertical'. Confirm selection by pressing . Use
to return to the set-up screen.
g. Configure the machines as appropriate. (Refer to set-up in chapter
1).

3-9
Flanged machines

h. Enter machine dimensions as described in chapter 1.

i. When entering machine dimensions, the flange geometry must be


to highlight the flange-mounted
taken into account. Use
machine and then press . The machine type screen shown below
appears.

j. Press . The context menu as shown overleaf appears. Use


to select 'Flange'.

or

ROTALIGN Ultra_III 01.05

3-10
Flanged Machines

k. Press
to confirm selection. The machine flange screen as seen
below appears.
The screen opposite is used to
configurate the shape and type of
the mounting, its center and bolt
pattern.

ROTALIGN Ultra_III 01.05

l. It may be necessary to edit the bolt coordinates. To do this, press


while in the machine flange screen. The context menu as
or
to select 'Bolts'.
shown overleaf appears. Use

3-11
Flanged machines

m. Press
to confirm selection. The machine bolts screen as seen
below appears.
This screen shows the polar and
cartesian coordinates of the bolts
relative to the chosen flange center.

ROTALIGN Ultra_III 01.05

3-12
Flanged machines

Note

and proceed to

For vertical alignment, static measurement mode is selected


automatically.

b. Rotate the shafts to the first measurement position. The reference


mark and the measurement position 0 must be level.
to take the first measurement point.
c. Press
d. Rotate shaft to the second measurement position (e.g. 1:30). If the
measurement position does not correspond with the selected
.
position, move the screen hour hand using
(If the measurement positions are marked counterclockwise, the
shafts should be turned clockwise.)
e. A minimum of three measurement positions are required to obtain
results, but it is recommended that a maximum number of
measurement points be taken to improve the quality of results.

ROTALIGN Ultra_III 01.05

3. Measure
a. After entering the required dimensions, press
center the laser beam.

3-13
Flanged machines

4. Results
to evaluate results.
a. Press
The results screen shows the
coupling gap and coupling offset in
the 0-6 (S) and 3-9 (T) directions.
Offset corrections in the S (side)
and top (T) directions are also
shown.
In this example, the side (S) correction indicates moving the flange by
0.11 mm towards 6:00 and by 0.12
mm towards 9:00.

Sign convention
POSITIVE GAP opens towards 0:00 or 3:00
POSITIVE OFFSET if the top machine is towards 0:00 or 3:00

b. To obtain the shimming corrections for each flange bolt, press


while in the results screen. The context menu as shown below
appears.

ROTALIGN Ultra_III 01.05

Use

or

to select 'Details'. Press

to confirm selection.

)
Note

3-14
Flanged machines

The flange corrections screen shows


the shimming corrections for each
flange bolt. The value for each bolt
position appears on the shim table
and as an inset next to the flange
pattern. Any bolt position can be
(counterselected using either
(clockwise).
clockwise) or

c. To choose the shimming solution best suited for the situation at


while in the results screen. The context menu as
hand, press
shown below appears.

)
Note

to select desired mode, confirming selection by pressing

() mode indicates all positive shimming


(+) mode indicates all positive shimming
() mode indicates optimized shimming. In this mode, half of the
corrections will positive, and the other half negative.
(0+) mode indicates zero plus shimming. In this mode, one bolt
position is forced to zero and the rest are positive.
(0) mode indicates zero minus shimming. In this mode, one bolt
position is forced to zero and the rest to negative.
Good quality shims such as LAMIBLOC and PERMABLOC should be
used.

ROTALIGN Ultra_III 01.05

Use
.

3-15
Flanged machines

d. It may be necessary to switch the view from say side (S) to top (T),
and vice versa. From the result screen, press . The context menu
to select desired view, confirmas shown below appears. Use
ing selection by pressing .
Side view (S) is selected by highlighting V, and top view (T) is
selected by highlighting H.

e. Offset is corrected using the 'MOVE' function. From the result


screen, press . The context menu as shown below appears.

ROTALIGN Ultra_III 01.05

Use
or
to select 'Move'. Press
to confirm selection. The
sensor position selection screen shown on the next page appears.

3-16
Flanged machines

f. Use
to position the sensor image on the screen to correspond
to the physical position of the laser and the receiver. Press
to
confirm selected position.

)
Note

If the Move function does not auto start, the beam is not centered.
ROTALIGN Ultra will automatically switch to XY view. After
and wait for the Move function
centering the laser beam, press
to auto start.

ROTALIGN Ultra_III 01.05

g. The Move function auto starts.

3-17
Flanged machines

5. Alignment
Correct angularity first:
a. Loosen the flange bolts and lift the upper machine to a small
degree.
b. Adjust shimming to make angularity corrections:
For face-mounted flanges, insert the indicated thickness of shims
between the flanges at the respective bolt locations.
For reverse-mounted flanges, insert the indicated thickness of
shims behind the flanges at the respective bolt locations.
c. Tighten the bolts back down, then take another set of readings to
confirm alignment corrections; repeat shimming if necessary.
d. Once satisfied that overall angular misalignment is in tolerance,
and no more shimming is required, proceed to correct offset.
Correcting offset misalignment:
while in the results screen. Preferred is a results screen
e. Press
showing both top (T) and side (S) alignment results.
f. From the context menu that appears, select 'Move' using either
or
, and confirm selection by pressing .
g. Ascertain which position your laser and receiver are located or
to match the sensor
turn them to any desired position. Use
position on the screen to the physical position of the laser and
receiver.
to confirm selected position.
h. Press
i. Loosen the flange bolts and perform offset corrections in the 12 to
6 (S) and 3 to 9 (T) o'clock directions while monitoring the live
move on the screen.
Corrections should be brought as close as possible to zero.
Use appropriate tools (e.g. levers) to position the machine.
Take care not to let the shims slip out of place during lateral
positioning.

j. When offset is in tolerance, tighten the flange bolts. Remeasure to


check if the new alignment condition is in tolerance.
k. If not, repeat the above steps until alignment is in tolerance.

)
Note

ROTALIGN Ultra_II 02.05

3-18
Tolerances

Suggested alignment tolerances


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.
To use the table, consider all values listed to be the maximum
allowable deviation from the alignment target, be it zero or some
desired value to compensate for thermal growth. In most cases, a
quick glance at the table will tell whether coupling misalignment is
allowable or not.
As an example, a machine running at 1500 RPM has coupling offsets
of -0.04 mm vertically and +0.02 mm horizontally: both these values
fall within the "excellent" limit of 0.06 mm. Or, in inches: e.g. at 1800
rpm offsets are -1.3 mils vertically, and +.6 mils horizontally: both
values fall within "excellent" limit of 2 mils.
Angularity is usually measured in terms of gap width at the edge of
the coupling. For a given amount of angularity, the larger the
diameter, the wider the gap at the coupling edge. The table lists
values for coupling diameters of 100 mm or 10". You may compare
results directly by entering this coupling diameter into ROTALIGN
Ultra, or alternatively, if actual coupling diameter is entered, then
multiply the value from the table by the appropriate factor.

"Acceptable" limits are calculated from sliding velocity of lubricated


steel on steel, using a conservative value of 12 mm/sec. (0.5 in./sec.)
for allowable sliding velocity. These values also coincide with those
derived from elastomer shear rates, so they also apply to short
couplings with flexible elements. The "excellent" values draw on
vibration observations made upon a wide variety of industrial
machines to determine the critical misalignment for vibration;
however, compliance with these tolerance values does not guarantee
vibration-free operation of a particular machine. Since rigid (fixed)
couplings have no tolerance for misalignment, they should be aligned
as accurately as possible.

ROTALIGN Ultra_II 02.05

For example, a machine running at 1500 rpm has a coupling of


diameter 75 mm. At this diameter, the maximum allowable gap
would be (0.07 mm) x 75/100 = 0.0525 mm (or 5/100 mm).
Or, in inches: at say 1800 rpm, diameter = 20": 5 mils x 20"/10" = 10
mils gap.
For spacer shafts, the table gives the maximum allowable offset for
each 100 mm or inch of spacer shaft length. To take an example; a
machine running at 6000 rpm with a 300 mm spacer shaft installed
would allow a maximum offset of (0.03 mm) x 300/
100 = 0.09 mm (or 9/100 mm) at either coupling at the ends of
the spacer shaft.
In inches: e.g. 7200 rpm, with length = 10": 0.25 mils x 10"/1" = 2.5
mils offset.

3-19
Tolerances

Suggested Shaft Alignment Tolerances


Tolerance
[RPM]
Soft foot

Angularity
(gap difference at coupling edge
per 100 millimeters diameter
or per 10" diameter)

inch [mils]

0.06 mm

2.0 mils

any

Short "flexible" couplings


Offset

metric [mm]

Acceptable
600
750
900
1200
1500
1800
3000
3600
6000
7200

600
750
900
1200
1500
1800
3000
3600
6000
7200

Excellent

0.19

Acceptable

Excellent

9.0

5.0

6.0
4.0

3.0
2.5

3.0

2.0

1.5

1.0

1.0

0.5

15.0

10.0

10.0
8.0

7.0
5.0

5.0

3.0

3.0
0.02
2.0

2.0

3.0

1.8

2.0
1.5

1.2
0.9

1.0

0.6

0.5

0.3

0.3

0.2

0.09

0.09

0.06

0.06

0.03

0.03

0.02

0.13

0.09

0.07

0.05

0.04

0.03

0.03

1.0

Spacer shafts and


membrane (disk) couplings
Offset
(per 100 millimeters spacer length
or per inch of spacer length)

600
750
900
1200
1500
1800
3000
3600
6000
7200

0.25

0.15

0.12

0.07

0.07

0.04

0.03

0.02

mrad
Angularity (mrad)
(angle between spacer and shaft)

ROTALIGN Ultra_II 02.05

600
750
900
1200
1500
1800
3000
3600
6000
7200

Note:
Metric tolerances are given for machines with a 50 Hz
supply running at multiples/fractions of 3000 RPM.

2.5

mrad
3.0

1.8

2.0
1.5

1.2
0.9

1.0

0.6

0.5

0.3

0.3

0.2

1.5

1.2

0.7

0.7

0.4

0.3

0.2

Inch tolerances are given for machines with a 60 Hz


supply running at multiples/fractions of 3600 RPM.

3-20
Index

Index

Adjustment tube 1-19


Adjustment wheels 1-19
ALI 2.230
magnetic sliding bracket 2-3
ALI 3.581-2
ROTALIGN receiver cable 1-10
ALI 3.608 1-19
adjustment tube 1-19
ALI 4.503
USB-peripheral devices cable 1-32
Alignment
cardan shafts 17
tolerances 19
tolerances, suggested 18
Angularity
correction 17
Automatic measurement 1-20
Averaging 2-16

B
Bolt
coordinates 3-10
pattern 3-10
Brackets
compact chain-type 1-9
mounting 1-8

C
Cable clip 1-9
Characters
lower case 1-13
upper case 1-13
Clock positions 2-2
Contents 1-3
Counterclockwise 3-6, 3-12
Coupling
results format 2-19
Coupling properties 1-16
Coupling targets 1-16, 1-17
Coupling type 1-16, 2-19
Customization 1-31

D
Deactivating measurements 2-13
Device configuration 1-5
Dial gauge mode 2-5
Dimensions
entering 1-12

E
Extend
measurement range 2-15

F
File
printing 1-32
saving 1-30
Flange
bolt 3-6, 3-13
corrections 3-14
Flange-mounted 3-6
Flanged machines 3-1

G
Global menu 1-30

H
History 2-9
label 2-11

I
Inclinometer
electronic 3-6
external 2-2

L
Laser
beam adjustment 1-19
mounting 1-9
Licence code 1-5
Licence manager 1-5
Locking knobs 1-19

M
Machine
fixation 1-14, 2-17
flange-mounted 3-6
mounting 2-17
preparing 1-7
trains 3-1
Machine flange 3-10
Machine properties 1-12
Machine trains 3-1
Machine type 1-14
Measurement
automatic 1-20
deactivating a point 2-13
extend 2-15

ROTALIGN Ultra_II 02.05

3-21
Index

history 2-9
pass mode 2-3
table 2-8
Measurement mode
continuous sweep 1-21
multipoint 2-2
pass mode 2-3
static measurement 2-2
Measurement modes 1-21, 2-1
Measurement point
deactivate 2-13
Measurement table 2-8
label 2-10
Mount
brackets 1-8
laser 1-9
receiver 1-9
v-foundation 2-17
Move 3-15
auto start 3-16
horizontal 1-26
vertical 1-26

Thermal growth
entering values 1-15
Thermal length calculator 225
Toggle point 2-13
Tolerance
suggested 18
Tolerance envelopes 1-24
Tolerance table 2-24
Tolerances 2-23
suggested values 19
Top view 3-13
Train orientation 3-8

Nonrotatable shafts 1-21

O
Offset
correction 17
Option
coupling targets 2-23

P
Pass mode 2-3
Print
report 1-33

ROTALIGN Ultra_II 02.05

Raw data
edit 2-13
Receiver
connecting 1-10
mounting 1-9
Receiver cable 1-10
Reference position
shaft 3-6
Registration key 1-6
Results
context menu 1-24
Resume policy 1-11

Save
measurement file 1-30
Shimming 1-26, 3-14
Shims 1-28
LAMIBLOC 1-28, 3-14
PERMABLOC 1-28, 3-14
Side view 3-13
Sign convention 1-25, 223, 3-13
Sleeve bearings 1-21
Sliding velocity 18
Smiley 1-25
Soft foot 1-7, 2-26
angular 2-26
checking 2-27
correction 2-30
diagnosis 2-31
parallel 2-26
Standard deviation 1-22

U
Uncoupled shafts 1-21
USB cable 1-32

V
V-shaped supports 2-18

W
White metal bearings 1-21

X
XY view 1-27, 2-15, 3-16

PRFTECHNIK Alignment Systems


Oskar-Messter-Strae 15
D-85737 Ismaning, Germany
www.pruftechnik.com
Tel:
+49 (0)89/ 99616-0
Fax: +49 (0)89/ 99616-100
eMail: info@pruftechnik.com
Printed in Germany ALI 9.845.02.05.G
ROTALIGN LEVALIGN NOVALIGN and smartALIGN are a
registered trademarks of PRFTECHNIK Dieter Busch AG. PRFTECHNIK products are the subject of patents granted and pending throughout the world. Contents subject to change without
further notice, particularly in the interest of further technical
development. Reproduction, in any form whatsoever, only upon
express written consent of PRFTECHNIK.
Copyright 2005 by PRFTECHNIK AG

Productive maintenance technology