ALI 12.200 EX Rotalign - Operating - Handbook PDF

ROTALIGN® smart EX
Operating handbook - Shaft alignment
PRÜFTECHNIK
Alignment Systems GmbH
Freisinger Str. 34
85737 Ismaning
Germany
Tel +49 89 99616-0
PROVEN QUALITY
Fax +49 89 99616-100
Made in Germany info@pruftechnik.com
Global Presence www.pruftechnik.com
Qualified Support
Quality Service
A member of the PRÜFTECHNIK Group
A user’s handbook
Dear Customer,
Welcome to laser shaft alignment using ROTALIGN® smart EX. This ROTALIGN smart
EX 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.
PRÜFTECHNIK Alignment Systems GmbH

Freisinger Str. 34
85737 Ismaning
Germany
Fax +49.89.99616-100
Email info@pruftechnik.com
1
Edition March 2011
Order number DOC 12.200.en
Firmware version 1.2x
ROTALIGN® is a registered trademark of PRÜFTECHNIK Dieter Busch AG. PRÜFTECHNIK

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 PRÜFTECHNIK Alignment Systems GmbH.
© Copyright 2011 by PRÜFTECHNIK Alignment Systems GmbH
ROTALIGN smart EX handbook
Foreword
ROTALIGN smart EX is a replacement system for the proven ROTALIGN PRO EX. This
new intrinsically safe system combines the proven OPTALIGN smart EX computer
[“ROTALIGN smart EX edition] with the technical capabilities of the 5-axis ROTALIGN
EX sensor, resulting in a high-end laser alignment system for use in explosive atmos-
pheres. The computer with its ergonomic design and intuitive operation is user-friendly.
It features an alphanumeric keyboard with strategically placed navigation keys that
handles all data entry functions. The computer has a high resolution backlit colour TFT
screen, handy on-screen context menu, computer LEDs that give the instant status of
the alignment condition and a remarkable file storage capacity.
The 5-axis ROTALIGN sensor contains two fully-linearized biaxial position detectors
and a precision inclinometer, making it possible to precisely measure relative motion
in five degrees of freedom – horizontal parallel displacement, vertical parallel displace-
ment, horizontal angular displacement, vertical angular displacement and rotation
about the longitudinal axis (i.e. shaft rotation angle).
ROTALIGN smart EX possesses powerful features that include among others, user-
definable stationary feet, single bearing machines, horizontal bolt-flanged machines,
various coupling types, wide selection of measurement modes to handle different
restrictions, thermal growth entry in terms of “target” coupling misalignment or
thermal growth amounts expected at machine feet, pipe strain and quick check
measurement.
The system is delivered together with ALIGNMENT REPORTER, a PRÜFTECHNIK

2
Alignment Systems freeware used for generating and printing measurement reports.
If you have any suggestions for improvement or corrections (not just to this manual,
but also for hardware), please drop us a line. We would be glad to make improve-
ments wherever possible.
We look forward to hearing from you.
PRÜFTECHNIK Alignment Systems

March 2011
Ismaning, Germany
Contents
Contents
A user’s handbook ............................................................................................................... 1
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Chapter 1: ROTALIGN smart EX package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

ROTALIGN smart intrinsically safe package ALI 12.001 EX .................................................... 5
Chapter 2: Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Operating information ........................................................................................................ 13
Chapter 3: ROTALIGN smart EX – an overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Description ......................................................................................................................... 17
Power supply ...................................................................................................................... 18
Laser and sensor ................................................................................................................ 21
Compact chain-type bracket ALI 2.892 SET ......................................................................... 24
Chapter 4: Configuration and data management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Shortcut numbers ............................................................................................................... 25
Configuration ..................................................................................................................... 25
Chapter 5: Horizontal machine alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1. Preparing for the alignment procedure ........................................................................... 41
2. Check for soft foot ......................................................................................................... 42
3. Mount the brackets ....................................................................................................... 42
4. Mount ROTALIGN laser and sensor ................................................................................. 44
5. Connect the sensor ........................................................................................................ 45
6. Switch the computer on and start application ................................................................. 46
7.1 Enter machine dimensions ............................................................................................ 46
7.2 Machine set-up ............................................................................................................. 49 3
7.3 Laser beam adjustment ................................................................................................. 64
8. Take measurements ........................................................................................................ 66
9. Results ............................................................................................................................ 67
10. Align machine............................................................................................................... 75
11. Saving data and printing ............................................................................................... 82
Chapter 6: Quick check measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Soft foot ............................................................................................................................. 91
Checking and correcting soft foot conditions ...................................................................... 92
Parallel soft foot correction ........................................................................................... 97
Angular soft foot correction.......................................................................................... 97
Checking pipe strain ........................................................................................................... 98
How the function works ............................................................................................... 98
Chapter 7: Dynamic alignment features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Measurement modes ........................................................................................................ 103
Multipoint measurement ............................................................................................ 104
Static measurement .................................................................................................... 104
Pass mode ................................................................................................................. 106
Special measurement features ........................................................................................... 108
Extending the measurement range ............................................................................. 108
Remeasuring .............................................................................................................. 110
Resume ...................................................................................................................... 111
Averaging ................................................................................................................... 111
XY View ..................................................................................................................... 113
Chapter 8: Special alignment applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Machine train alignment ................................................................................................... 115
Cardan drive machines...................................................................................................... 125
Flanged machines ............................................................................................................. 131
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Suggested shaft alignment tolerances ............................................................................... 145
“ROTALIGN smart EX edition” technical data .................................................................... 147
Attachments ..................................................................................................................... 149
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
4
ROTALIGN smart EX packages
Chapter 1: ROTALIGN smart EX package
ROTALIGN smart intrinsically safe package ALI 12.001 EX
ALI 12.801 EX Intrinsically safe ROTALIGN smart case
ALI 12.200 EX OPTALIGN smart intrinsically safe version

computer including approved batteries
[“ROTALIGN smart EX edition”]
ALI 12.201 Computer stand
t
® smar
GN
TALI
RO
art EX
LIGN® sm
ROTA
ALI 12.801 EX ALI 12.200 EX ALI 12.201

ALI 3.600-2 EX Intrinsically safe ROTALIGN sensor

including dust cap ALI 3.606
ALI 3.610 EX Intrinsically safe laser including dust cap

ALI 3.607
ALI 12.500 Adapter box for intrinsically safe

[“ROTALIGN smart EX edition”] computer
ALI 12.500 The adapter box

ALI 12.500 is not intrinsi-
USB port for
6 data transfer to PC
cally safe and is not to be
used within an explosive
environment.
USB port for printer

connection
AC power supply port
ALI 3.600-2 EX ALI 3.610 EX

ALI 12.511-2 Sensor cable connected to instrinsically

safe [“ROTALIGN smart EX edition”]
computer
ALI 12.651-I AC power supply/charger for adapter

box
ALI 12.504-2 USB A/B cable for connecting to printer or PC
ALI 4.452 USB memory stick
ALI 2.892 SET Compact chain-type bracket without

pouch
ALI 12.651-I ALI 4.452
ALI 12.511-2
ALI 12.504-2 ALI 2.892 SET

ALI 12.701 OPTALIGN smart shaft

firmware certificate
ALI 2.905 Lens cleaning cloth
ALI 3.588 EX Intrinsically safe tape measure mm/inch
DOC 12.100.en ROTALIGN smart EX pocket guide
DOC 12.200.en ROTALIGN smart EX operating

instructions
PowerLock®
C L A S S I C
3,5m/12‘
ALI 2.905 ALI 3.588 EX

DOC 12.200.en DOC 12.100.en
ALI 13.700 CDS ALIGNMENT CENTER CD/Resources CD
ALI 13.701 CD ALIGNMENT REPORTER CD
ALI 3.608 Beam adjustment tube
0 0739 1055 Allen key – 2.5 mm [used to undo the

computer and laser battery compart-
ments]
0 0739 1057 Allen key – 4 mm [used to lock/unlock

the ROTALIGN smart EX case flap and for
assembling/disassembling the support
posts]
ALI 13.701 CD
0 0739 1055 — 2.5 mm (3/32”)
0 0739 1057 — 4 mm (5/32”)
ALI 13.700 CDS

ALI 3.608
This page intentionally left blank
10
Safety notes
Chapter 2: Safety notes

ROTALIGN smart EX is to be used in industrial environments only for shaft alignment.
Care must be taken to ensure that the instrument is not subjected to mechanical
knocks. ROTALIGN smart EX must be operated only by properly trained personnel. No
liability will be assumed when components or operating procedures as described in
this manual are altered without permission of the manufacturer.
Safety symbols
The following symbols are used in this manual in order to draw the reader’s attention
to especially important text, such as that regarding possible sources of danger or
useful operating tips.
This symbol denotes general information and tips regarding operation of

ROTALIGN smart EX. Note
This symbol denotes information which must be followed in order to avoid

damage to equipment.

CAUTION
This symbol denotes information which must be followed in order to avoid

personal injury.
WARNING
Numbers in red circles indicate the corresponding operating step described in 1

these instructions and must be performed exactly.
CE compliance and EMC

11
ROTALIGN smart EX fulfills the EC Guidelines for electric devices and those relating to
electromagnetic compatibility (2004/108/EC).
ROTALIGN smart EX has been tested to the scope of:

› DIN EN 61326-1; VDE 0843-20-1 › EN 60079-28:2007
› DIN EN 61326-2-2; VDE 0843-20-2-2 › IEC 60079-0:2004
› EN 60079-0:2006 › IEC 60079-11:2006
› EN 60079-11:2007 › IEC 60079-28:2006-08.
IP classification
The computer is dust-tight and protected against water jets (IP65). The sensor and
laser comply with code IP67 (dust-tight and protected against immersion).
Notes for intrinsically safe models

In addition to the general notes described previously, the following notes must strictly
be observed when working in explosive atmospheres.
When equipment to be aligned is located in an explosive environment, the

intrinsically safe computer ALI 12.200 EX [“ROTALIGN smart EX edition”]
and the intrinsically safe ROTALIGN sensor ALI 3.600-2 EX with serial
number range xxxx 8xxx must be used.
Batteries must be changed only outside the explosive area! Note that only
alkali-manganese batteries can be used in explosive atmospheres. With
the computer [“ROTALIGN smart EX edition”], use only 1.5V AA MN 1500
batteries from Duracell or the reachargeable batteries AccuCell AC 1800

WARNING
(ALI 2.811). With the intrinsically safe laser ALI 3.610 EX use only the 9V
alkaline manganese block battery (Duracell Procell MN 1604).
The ROTALIGN smart EX case ALI 12.801 EX may be taken into the
hazardous area.
The circuit parameters meet the intrinsic safety requirements Ex ib IIC.
The maximum cable length between the computer [“ROTALIGN smart EX

edition”] socket and the sensor must not exceed 10 m.
The interfaces for USB host and device, and the 12 V supply are not
certified for use in explosive environments and therefore its use must take
12 place outside the hazardous zone, and must be connected via the adapter
box ALI 12.500.
The adapter box ALI 12.500 is not intrinsically safe and must therefore be
used outside explosive atmospheres.
Devices that rely on the power supply to the USB host for initiation (for
example the USB memory sticks) must only be connected to the adapter
box ALI 12.500 outside the explosive area.
The intrinsically safe computer [“ROTALIGN smart EX edition”] may be

powered using the AC power supply/charger ALI 12.651-I as long as the
power supply /charger is only used outside the hazardous area, and is
connected via the adapter box ALI 12.500.
Safety notes
The installation and operation of the intrinsically safe ROTALIGN smart EX

must be in accordance with the European regulations (EN 60079-10:2003
ff) and equipment safety law as well as the general recognised rules of the
technology and this operating manual.

The most current regulations regarding servicing, maintenance and testing,
as they appear in EN 60079-14 and EN 60079-17 must be observed. The
rules of the manufacturer as they appear in this manual must also be
WARNING
observed.
The EC type examination certificates (ATEX) and the IECEx certificates of

conformity are attached in the appendix.
Laser safety
The intrinsically safe system laser ALI 3.610 EX uses a class II laser beam. Class II
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. It also fulfills British
standard BS 4803 (Part 1 to Part 3) and European Industrial Standard IEC 825. The
class II laser operates at a wavelength of 675 nm, with a maximum pulse duration of
128 μs, maximum radiant power of 0.8 mW and maximum radiant energy per pulse
of 0.1 μJ. No maintenance is necessary to keep this product in compliance with the
specifications referred to.
Do not look directly into the laser beam at any time. (Since FDA specifica-
tions allow maximum exposure of 0.25 seconds, the natural blink reaction
of the human eye would normally be sufficient to avert any danger,

WARNING
13
provided that no optical instruments other than ordinary eye glasses or
contact lenses are used. But as natural blink reaction may fail to occur, care
should be taken to avoid staring into the beam.)
Do not insert any optical devices into the beam path.
The red LED on the front of the laser illuminates whenever the laser beam
is emitted.
Operating information
Temperature range
ROTALIGN smart EX and its related system components must be used at temperatures
between 0° and 45° C (32° to 113° F). Outside of this range, the specified accuracy
may not be maintained.
Store the system and its related components at temperatures between -20° C and 60°
C (-4° F to 140° F).
Temperature effects and fluctuations

Powerful heat sources or steam located near the laser beam could influence the
accuracy of measurements as a result of beam deflection. In practice, however, this
effect occurs seldom at distances up to 1 m. If in doubt, the effect can be elimi-
nated by shielding the system from the heat/steam source during measurement and
adjustment.
As with all precision optical measurement devices, sudden fluctuations in tempera-
tures (e.g. resulting from sunlight), could result in erroneous measurements.
Allow adequate time for ROTALIGN smart EX and its related components to
reach the ambient temperature.

Note
Incident light
Avoid exposing the system to strong, hot light such as direct sunlight.
Dust and water seals

The intrinsically safe computer [“ROTALIGN smart EX edition”] is water and contami-
nation resistant to specification IP65; the sensor and laser are resistant to specification
IP67. This specification requires that each component be able to withstand a water
jet spray from any direction (the components are NOT guaranteed to withstand a
full submersion). As with most water-resistant products, the resistance must be peri-
odically checked. This can be carried out during service and calibration check of the
system which is recommended to be carried out every two years.
Interface connection
The single interface of the intrinsically safe computer [“ROTALIGN smart EX edition”]
14 connects via the adapter box ALI 12.500 for data exchange with a PC/printer, the
sensor as well as mains supply.
Note regarding data storage

With any data processing software, data may be lost or altered under certain
circumstances. PRÜFTECHNIK strongly recommends that you keep a backup or
Note
printed records of all important data.
PRÜFTECHNIK assumes no responsibility for data lost or altered as a result of

improper use, repairs, defects, battery replacement/failures or any other cause.
PRÜFTECHNIK assumes no responsibility, directly or indirectly, for financial losses

or claims from third parties resulting from the use of this product and any of its
functions, such as loss or alteration of stored data.
Component labelling
Any waste electrical and electronic parts of the ROTALIGN smart EX system
including memory sticks must be disposed off in accordance with the WEEE
(Waste Electrical and Electronic Equipment) Directive. Such parts must be taken
to the nearest collection facility.
Component labelling
The labels shown below are to be found on the rear of the intrinsically safe computer
[“ROTALIGN smart EX edition”] ALI 12.200 EX, sensor ALI 3.600-2 EX and laser ALI
3.610 EX.
These two labels are

affixed to the back of the
NiCd intrinsically safe computer

[“ROTALIGN smart EX
edition”].
Use only ATEX certificated dry cells, or the
rechargeable batteries ALI 2.811!
00 0 9E
PRÜFTECHNIK AG 85737 Ismaning II 2G Ex ib [ib] IIC T4, -10°C <Ta< 50°C

TÜV 08 ATEX 554162
OPTALIGN®smart 0044 IECEx TUN 08.0006
These two labels are

located at the bottom of
the computer [“ROTALIGN
smart EX edition”].
15
On the back of the

intrinsically safe sensor
ALI 3.600-2 EX is an
amalgamation of two
12 labels – the calibration
label (shown opposite in
green - note that the white
arrow points to the month
when the sensor calibration
is due. The year appears
under the “db” logo), and
the main sensor label.
This label is affixed to the

back of the intrinsically safe
laser ALI 3.610 EX.
These two laser safety labels

are attached on the front of
the intrinsically safe laser.
16
Introducing ROTALIGN smart EX
Chapter 3: ROTALIGN smart EX – an overview
Description
The “ROTALIGN smart EX edition” computer keyboard at a glance

The computer possesses 3 function keys.
d The ‘Dimensions’ key is used to initiate entry of machine dimensions.

m The ‘Measurement’ key is used to start the measurement process.
k The ‘Result’ key is used to call alignment results into the display.
ß The ‘Up’ key is used to confirm entered values, and as a back/return key,
taking user to previously selected screen.
c The ‘Clr’ (Clear) key is used to delete information entered inadvertently.

q The ‘Menu’ key offers a choice of procedures for setting up the computer
and proceeding with different alignment situations.
h i f g The navigation keys are used to navigate through the

program steps.
e The ‘On/Off/Enter’ key is used to perform the dual function of switching

on the computer, confirming entered values and accessing any selected item. To
switch the computer on, press the ‘On/Off/Enter’
1 The data entry keys are used to enter relevant machine data.
17
1 2 3 4
1. Sensor socket / Adapter box
socket
2. Function keys
5 3. Up / Clear / Menu keys
4. Navigation keys
5. On/Off/Enter key
6
6. Data entry keys
7. Battery status LED
8. Alignment condition LEDs
ROTALIGN® smart EX
8 7
Power supply
The intrinsically safe computer ALI 12.200 EX [“ROTALIGN smart EX edition”] is

powered using six ‘AA’ size batteries. Alternatively, the computer may be powered
outside explosive environments using the AC power supply/charger via the adapter
box ALI 12.500.
The batteries allow operation of up to 18 hours (25% active measurement, 25%

standby, 50% ‘sleep’ mode).
Batteries for intrinsically safe version

The intrinsically safe computer ALI 12.200 EX [“ROTALIGN smart EX edition”] requires
special attention with regard to batteries.
Only alkali-manganese batteries of the type listed below is to be used with the
intrinsically safe version:
› 1.5 V “AA” MN 1500 from Duracell
› AccuCell AC 1800 rechargeable battery
Otherwise, intrinsic safety may be compromised.

Be sure to remove the “ROTALIGN smart EX edition” computer from the explosive
environment before changing batteries.
DO NOT USE lithium batteries or nickel-cadmium rechargeable batteries in
WARNING
explosive environments.
Replacing batteries
If batteries require removal, turn over the computer taking care not to damage the
18
display and the hard keys. Undo the two half-turn
screws by rotating them at least 180° (1/2 turn) using
a 2.5 mm allen key. With the screws loosened, lift and

Bab
y LR
No 14
4014 C AM2
1,5
V
Bab
y LR
pull out the battery compartment cover. The reverse

No 14
4014 C AM2
1,5
V

Bab

y LR

No14

4014 C AM2

1,5
V
procedure is used to reinstall the battery compartment Bab

y LR
No14
4014 C AM2
1,5
V
Bab
cover.
y LR
No 14

4014 C AM2
1,5

V

Bab
y LR
No14
4014 C AM2
1,5
V
With the intrinsically safe

computer [“ROTALIGN
smart EX edition”], the
battery compartment is
within the computer and
therefore batteries are
placed directly into the
computer.
It is recommended to replace all six ‘AA’ size batteries at the same time. Note the
battery polarity when inserting them in the battery compartment.
Used batteries should be disposed of in an environmentally responsible manner

in accordance with applicable regulations!

If the intrinsically safe computer [“ROTALIGN smart EX edition”] is not in use for
extended periods of time, a month or more, the batteries should be removed
from the unit.

CAUTION
The charge level of the battery is displayed by pressing q. The context menu appears
showing the current battery capacity.
battery charge level

19
Connection of peripheral
devices ( PC, printer , USB
stick, and power supply)
Interface for data The USB memory stick is Note: The USB memory
to an intrinsically safe
exchange with a PC/ connected directly to the stick and printer interfaces
computer [“ROTALIGN
printer and power supply adapter box. cannot be used simultane-
smart EX edition”]
to the intrinsically safe Note: No other device is to ously.
only takes place via the
computer [“ROTALIGN be connected to this specific
adapter box ALI 12.500.
smart EX edition”]. port.
The adapter box must
under no circumstances be
used in a hazardous area.
AC power supply/charger
ALI 12.651-I
20
Connected to printer using the USB A/B cable ALI 12.504-2
Connected to PC using the USB A/B cable ALI 12.504-2

Laser and sensor
Laser ALI 3.610 EX

The semiconductor laser diode emits a ray of red light (wavelength 675nm) which is
visible where it strikes a surface. The beam is emitted with a diameter of approx. 5mm
(3/16”). Because the laser is operated in short pulses and not as a continuous beam,
its power is low enough to qualify for class II safety rating.
Do not stare into the laser beam!
The beam is adjusted during set-up by changing its vertical and horizontal angles with

WARNING
thumbwheels so that the beam strikes the sensor lens straight on.
The laser is water and dust resistant. The internal optics and electronics are internally
sealed, preventing possible contamination.
The battery compartment is not watertight. If water enters this compartment,

open it and dry it out. The battery should then be replaced.

CAUTION
Laser battery
The laser is powered by an alkali-manganese 9 V block battery (type IEC6LR61) —
Duracell Procell MN 1604. This provides a typical operating duration of 80 hours.
As the battery becomes depleted, the colour of the ‘laser active’ indicator LED
changes from red to yellow. When this occurs, the battery should be replaced.
CAUTION
If the laser is not in use for extended periods of time, a month or more, the
21
battery should be removed from the unit.
The battery is replaced by removing both screws from the battery compartment cover
of the laser housing using the provided 2.5 mm allen key.

Under no circumstances may the four smaller housing screws be removed,
as that would result in misalignment and would void all warranty coverage.
Used batteries should be disposed of in an environmentally-sound manner!
Sensor ALI 3.600-2 EX

The sensor contains two position detectors, which measure the exact position of the
laser beam as the shafts are rotated. The sensor also contains an electronic inclinom-
eter for shaft rotation measurements.
The sensor has two indicator LEDs on its front side, one green and the other red, to
indicate beam adjustment.
The sensor is powered by the computer [“ROTALIGN smart EX edition”] via the sensor
cable ALI 12.511-2 through which measurement data also pass.
Cable connection
Insert the angled plug into the sensor socket as shown; note the keyway indicating
proper plug orientation. Screw down the cable fitting to tighten the connection. The
angled plug should be left permanently connected to the sensor, even when storing
the system in its case, as this will help avoid damage to cable pins, plugs and sockets.
Never turn the plug itself, as that can damage the cable pins!
Note correct plug orientation indicated by the markings on the plug and the
socket.
CAUTION
Service and care
The calibration accuracy of the system should be checked every two years as
indicated by the date wheel label (shown at right) located on the back of the
sensor housing.
Note
Please return the system to your authorized PRÜFTECHNIK service centre for
Month
calibration checking by the date indicated.
12 Year
22
Laser ALI 3.610 EX Vertical beam position Laser complies with

adjustment thumbwheel 21 CFR 1040.10 and
Rubber housing 21 CFR 1040.11
Battery compartment
Horizontal beam position

thumbwheel
Locking knob
On/Off toggle switch
Replacing laser battery

“Beam active” indicator LED
DURACELL
MN1604 6LR61 9,0V
DURACELL N
O
TI
U .1
0
A 40
10 -
ALKALINE
C C
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21 1 se rr
ALKALINE
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FT 7
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P 85
-
D
Under no circumstances
Sensor
may the four smaller
ALI 3.600-2 EX Rubber housing 23
housing screws be removed,
as that would result in mal-
adjustment and would void
all warranty coverage.
Scratch-resistant lens
Cable socket
Locking knob
Compact chain-type bracket ALI 2.892 SET
Compact and lightweight, this universal chain-type bracket provides orderly and
convenient storage of all parts needed for quick, rigid mounting of the measurement
components. The bracket fits onto nearly any shaft or coupling approx. 15 mm to 500
mm / 5/8” to 20” in diameter.. Chains of varying lengths are also available. Mounting
instructions are given in ‘Horizontal machine alignment’. Other bracket types are also
available. Contact PRÜFTECHNIK Alignment Systems or your local representative for
details on additional accessories.
Compact chain-type bracket

Optional magnetic sliding
bracket ALI 2.230
24 Optional magnetic bracket

Optional extra-thin
set ALI 2.761 SET
bracket ALI 2.109 SET
Optional compact magnetic
bracket ALI 2.112
Configuration
Chapter 4: Configuration and data management
Shortcut numbers
“ROTALIGN smart EX edition” menu items are accessed using the navigation keys.
The navigation direction is either upwards/downwards or sideways. Alternatively, use
may be made of the data entry keys which provide navigation shortcuts.
All context menu items are labelled with digits for quick access. The required
menu item is accessed directly by pressing the corresponding data entry key.

Note
Configuration
The menu item ‘Configuration’ is used to configure the “ROTALIGN smart EX edition”
settings, the regional settings, default settings, shaft application settings, printing
settings and licencing of available applications.
With the computer switched on, access ‘Configuration’ by pressing q twice. The
expanded menu as shown below appears.
Alternatively, the
“Configuration” screen is
opened directly by pressing
7 when the expanded
menu appears.
25
With expanded menu displayed, use f/g to highlight ‘Configuration’, then

press e to confirm selection. The screen with items that can be configured appears.
Each item in the configura-

tion screen can be opened
by pressing the correspond-
ing data entry key (e.g.
pressing 6 opens the
“Shaft settings” screen).
Device settings
The “Device settings” screen is opened by pressing 1. Alternatively, use the
navigation keys to highlight the ‘Device settings’ icon then confirm selection by
pressing e to access the available settings. These include brightness, keyboard
beep, power scheme, battery level and boot up screen. Use f/g to select
item to be set.
26
The display brightness is adjusted using h/i.

Configuration
To turn the keyboard beep on/off, press e. The on/off box appears. Use f/g
to select either ‘on’ (to enable the beep) or ‘off’ (to disenable the beep). Press e to
confirm selection.
27
The power scheme option is used to select setting that manages the power usage
within the system computer. The four available options are: ‘Standard’ (the display
dims after 10 minutes and shuts down after 1 hour), ‘Full power’ (no dimming and
no shutdown), ‘Use standby’ (no dimming and shutdown is after 1 hour) and ‘Long
life’ (the display dims after 3 minutes and shutdown takes place after 10 minutes).
The required setting is selected using f/g and confirmed by pressing e.
The image to be uploaded

The capacity of the battery appears next to the battery level bar.
is saved in the approved
memory stick ALI 4.452
in .png format under
the name ‘companylogo’
together with a folder
named OPTALIGN.
Connect the memory stick
to the system computer
via the adapter box ALI
12.500. With ‘Boot up
screen’ highlighted, press
e and use f/g
to highlight the item
‘Find and set’. Confirm by
28 The item ‘Boot up screen’ is used to upload an image, such as the company logo, to
the system computer, that appears when the system is started or booted.
pressing e.
Configuration
‘Resume policy’ allows the user to specify the measurement file that opens when
the system computer is turned on. The system may be set to open the last used
measurement file (‘Always resume last file’) or open a new measurement file (‘Resume
manually’). The option may also be used to open measurement files based on date
last used. With ‘Resume policy’ highlighted, press e to display the available resume
options. Use f/g to highlight preferred resume option. Confirm selection by
pressing e.
Regional settings
This option is used to set the units of measurement, the preferred country language,
current date and time. The screen is opened by pressing 2 while in “Configuration”
screen. Alternatively, use the navigation keys to highlight the ‘Regional settings’ icon
then confirm selection by pressing e to access the available settings.
29
Highlighting ‘Units’ using f/g and confirming selection by pressing e

reveals the available units of measurement. These are the US units, the English units
and the SI (metric) units.
Select the required system of units using f/g. Press e to confirm

selection.
Highlighting ‘Language’ using f/g and confirming selection by pressing

e displays a list of the available country languages. Select the preferred country
language using f/g. Press e to confirm selection.
Highlighting ‘Time zone’ using f/g and confirming selection by pressing e

displays the different time zones. The required zone is selected using f/g and
confirmed by pressing e.
When a time zone is initially

highlighted, a hint appears
displaying major world cities
within the selected time
zone. Note that changing
the time zone automatically
alters the time set.
Current date and time are set by highlighting the respective option using f/g
and confirming selection by pressing e.
30
Use h/i to highlight either date, month or year.

Configuration
Set the date using the data entry keys and confirm entry using either ß or e.
Alternatively, both date and time can be set using f/g.
31
The format in which the date or time is displayed is set via the item ‘Date/time format’.
Open regional settings by pressing 2. Use f/g to highlight the menu item
‘Date/time format’.
Pressing e with ‘Date/time format’ highlighted reveals a menu box with the items
‘Date format’ and ‘Time format’. Use f/g to select either item, confirming
selection by pressing e.
The time format is used to set either the 12h or 24h notation. The selected notation
is confirmed by pressing e.
The date format is used to set dd-mm-yyyy or mm/dd/yyyy format.
32
Configuration
Default settings
The “Default settings” screen is opened by pressing 3 while in the configuration
screen. Alternatively, use the navigation keys to highlight the ‘Default settings’ icon
then confirm selection by pressing e to access the available settings. The screen is
used to set specific default parameters. The default changes are effective upon restart
or if a new file is created.
‘Results resolution’ is used to set the results resolution at either ‘Normal’ or

‘High’.
Alignment results and units used Result resolution normal Result resolution high
Coupling results ( mm / mrad ) 2 decimal places x.xx mm 3 decimal places ( 1 μm res. )

x. xxx mm
33
Foot results ( mm ) 2 decimal places x.xx mm 2 decimal places x.xx mm
Coupling results 1 decimal place 1 decimal place

( mils / mils per inch )
Foot results 1 decimal place rounded off to 1 decimal place xxx.x

( mils ) 1/2 mil ( 0.5 mil, 1 mil, 1.5 mils )
Default sensor is used to set the default sensor to either ROTALIGN or OPTALIGN
Workflow assistant has three options – ‘On’, ‘Sensor-coupling distance auto
calculation’, ‘Off’. The options determine the guidance steps required to carry
out an alignment job.
Licence manager
This option is used to licence all possible “ROTALIGN smart EX edition” applications.
The “Licence manager” screen is opened by pressing 4 while in the configuration
screen. Alternatively, use the navigation keys to highlight the ‘Licence manager’ icon
then confirm selection by pressing e to access the licence manager.
Use the navigation keys to

highlight the ‘Feature key’
and ‘Licence code’ boxes.
Enter the received key and
code values using the data
entry keys.
Use the data entry keys to enter the application licence code. Press e to activate
the application.
To find out which features are available on your particular instrument, press q while
in the “Licence manager” screen.
The menu item ‘About’

(described later within this
section) provides a quick
34 overview of important
information related to the
instrument and the installed
features.
Use either f or g to highlight ‘Feature list’. Press e to confirm selection.

Alternatively, access the features list directly by pressing 2 with the licence manager
context menu displayed.
Configuration
Use f/g to scroll

through the features list.
About application
The information contained under this section is accessed by pressing 3 with the
licence manager context menu open. The displayed information is depicts the current
status of the device and application.
35
Printer configuration
This option is used to set up printers and the printing configuration in “ROTALIGN
smart EX edition”. The “Printer configuration” screen is opened by pressing 5
while in the configuration screen. Alternatively, use the navigation keys to highlight
the ‘Printer configuration’ icon then confirm selection by pressing e to access the
printer configuration screen.
Four printing options can be set using ‘Printer configuration’.
‘Type’ – Selecting ‘Type’ and then pressing e displays a list with all supported
printers. Alternatively, ‘PDF file’ can be selected to save the report directly to a
USB memory stick.
‘Paper’ – Used to select the required paper size
‘Orientation’ – Used to set the paper orientation. Select ‘Portrait’ for a vertical
36 layout and ‘Landscape’ for a horizontal layout.
‘Color mode’ – Used to set the color mode in which the measurement report is
to be printed. This can either be in full color or in grayscale.
ALI 4.452 The measurement report

is saved as PDF to the
approved memory stick
ALI 12.500
via the adapter box ALI
12.500
ALI 12.200 EX
ALI 12.651-I
Configuration
Shaft settings
The “Shaft settings” screen is opened by pressing 6 while in the configuration
screen. Alternatively, use the navigation keys to highlight the ‘Shaft settings’ icon then
confirm selection by pressing e to access the available settings. The screen is used
to set specific shaft alignment parameters. The settings are effective immediately.
Spacer format – used to specify way in which spacer coupling results are
displayed
Tolerance envelopes show
Tolerance envelopes – used to activate or deactivate the tolerance envelopes
the bandwidth within
Machine shapes – used to activate or deactivate the option of selecting different
which the machines are to
machine graphics
be positioned to be within
All-in-one results – used to activate or deactivate the option to display both feet
the set tolerances.
and coupling results within a single screen
Default rpm – used to set the desired default rpm
Reference diameter – used to set the desired reference diameter 37
Cardan units – used to set the desired measurement unit

Tolerance table – the available options are 50 Hz and 60 Hz. The mains supply
frequency determines the standard rpm values that appear in the tolerance table.
Tolerance values based on these frequencies may be read off the suggested
PRÜFTECHNIK Alignment tolerance table.
Auto sweep – used to activate or deactivate ‘auto sweep’ [if deactivated,
continuous sweep measurement takes place only after pressing e]
Data management
“ROTALIGN smart EX edition” possesses an effective file and data management

facility. The file and data management options are accessed by pressing q twice.
Use h/i to cycle the

cursor between the two
panes.
Note: By ‘cursor’, we are
referring to the orange
highlight bar.
Use h to access the box with the file and data management options. These are
‘Open file’, ‘Save file’, ‘New file’, ‘Print’ and ‘About’.
‘Open file’ – This option is used to load any stored file. Pressing 1 with the cursor
on the left pane reveals a list consisting all stored files.
Alternatively, the ‘Open file’

option may be accessed
38
in the set-up screen above
using the navigation keys
to highlight ‘Open file’ then
pressing e.
Use f/g to highlight file to be opened and press e to open the file.
Configuration
‘Save file’ – This option is used to save the current file. If the file is new and does not
yet have a name, use the data entry keys to enter the new file name in the editing
box that appears.
Press either ß or e to confirm file name.

If the file name already exists, the editing box appears with the existing file name
highlighted. This may be overwritten or replaced with a new file name.
‘New file’ – This option is used to create a new measurement file.
‘Print’ – This option is used to save the measurement report as PDF directly to a
memory stick or print the report or the soft foot measurement report using any one
of the available printers.
39
The following report options are available:

› Complete report – this option prints a complete report that includes machine
graphics and measurement results in both numerical and graphical format.
› Graphical report – reports printed using this option display only graphical
representation
› Text report – this option generates reports only in text format
› Pipe strain measurement report – this option is used to generate the pipe
strain check report
› Change printer to configured printer – this item is used to toggle between
the default setting ‘PDF file’ and the configured printer. To configure a new
printer, press q while on this screen followed by 3, then proceed as
described under ‘Printer configuration’ previously.
40
Horizontal shaft alignment
Chapter 5: Horizontal machine alignment
1. Preparing for the alignment procedure
Before using the system, prepare the machine for alignment as described below.
Make sure machines are locked out and tagged out and cannot be started
accidentally or deliberately while you are working on them!
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 (50 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!). 41
Because of the measuring principle, “ROTALIGN smart EX edition” can distinguish
between coupling backlash and misalignment. During shaft rotation, the sensor and
laser must, however, make contact during some portion of the rotation.
e. Soft foot
Soft foot causes the machine frame distortion every time the anchor bolts are
tightened, 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 smart EX edition” requires no mechanical connections (such as Note: A maximum laser-
cantilevered dial indicator brackets) to span over the coupling during measurement, sensor separation of 10 m
alignment may easily be performed over large laser–sensor separations. (33 feet) is recommended.
Note that over very large distances the shafts and coupling may sag, and the machines
may need to be deliberately misaligned to take this into account, if such sag does not
disappear when machines are put into operation. Refer to the machine manufac-
turer’s specifications.
2. Check for soft foot
Refer to section on soft foot on page 91
3. Mount the brackets
Mount the brackets on either side of the coupling on either the shafts or on the solid
coupling hubs, and both at the same rotational position.
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!

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

CAUTION

bracket configuration supplied by PRÜFTECHNIK Alignment (for example,
do not use support posts longer than those supplied with the bracket).
WARNING
42 Bracket mounting procedure
To fit the compact chain brackets, refer to the diagram shown below and follow the
instructions carefully.
1. Choose the shortest support posts which will still allow the laser beam to pass
over or through the coupling. 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 in the diagram; 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.
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 PRÜFTECHNIK
Note
representative for details.
43
Anchor peg
1
3 4
2
4. Mount ROTALIGN laser and sensor
Mount the laser on the support posts of the bracket fixed on the shaft of the left
machine (usually reference machine), and the sensor 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 locking knobs are
loosened enough to let you slide the housing onto the support posts.
Clamp both the laser and the sensor onto the respective support posts by tightening
the yellow knobs. Ensure that the laser can pass over or through the coupling and is
not blocked. Fasten the sensor cable to one of the support posts using a cable clip.
Both the laser and sensor 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 rotationally aligned to each other.
Make the final adjustments, loosening the brackets slightly if necessary, then rotating
them and retightening.
In some cases, if the

coupling is large enough,
a coupling bolt can be
removed and the laser
beam shot through the
Locking knob bolt hole, in order to
avoid protruding radially
Laser
beyond the coupling‘s
outer diameter (O.D.).
Sensor
44
Mount just high enough

to clear coupling
Cable clip
5. Connect the sensor
Insert the straight-ended plug of the sensor cable ALI 12.511-2 into the sensor/USB/
charger socket on the top of the computer housing, with the red dot at the top.
Matching red dot
Match the red dot on the plug to the red marking on the socket to ensure proper
plug orientation; otherwise the pins inside the plug may be damaged.
Note 45
Disconnecting the sensor

To disconnect, grasp the ribbed collar of the sensor plug and carefully pull it out of
the control unit socket.
6. Switch the computer on and start application
Switch on the computer by pressing e. The system beeps followed by the flashing The splash screen may be
of the blue alignment condition LED. Shortly afterwards, the splash screen appears, set by the user to display
followed by the shaft alignment machine dimensions screen. a company logo or image.
This can be useful for
identification purposes.
7.1 Enter machine dimensions
Refer to page 28 for
information on how to
Machine information and dimensions are entered using the grey data entry keys.
do this.
The required missing dimensions are entered directly using the data entry keys. With
the missing dimension highlighted, enter dimension by pressing the appropriate data
entry keys. The editing box appears as soon as the first key is pressed.
46
Confirm the entered value by pressing e. The highlight advances automatically to

the next missing dimension. Alternatively, any dimension can be accessed by using
the navigation keys.
The dimensions to be entered vary according to machine and type of coupling. In a

standard horizontal alignment application enter dimensions as follows:
7.1.1 Coupling center to sensor

Distance marking
This is the distance between the marking on top of the sensor and the coupling center.
Should there be need to edit the value, simply highlight it using the navigation keys,
then use the data entry keys to edit the value directly.
7.1.2 Coupling diameter

The coupling diameter can be obtained by measuring the circumference of the
coupling and dividing the value by 3.142 (pi).
The default value is 100 mm (10” if set to US units). Should there be need to edit the
value, use the navigation keys to highlight the value, then use the data entry keys
to edit the value directly. Confirm the value by pressing e. The highlighting box
advances to the next required missing distance automatically.
7.1.3 RPM (revolutions per minute)

The default value is 1500 (1800 if set to US units). Should there be need to edit the
value, simply highlight it using the navigation keys, then use the data entry keys to
edit the value directly.
7.1.4 Coupling center to front foot, right machine

This is the distance from the centre of the coupling to the pair of feet on the right
machine nearest to the coupling.
7.1.5 Front foot to back foot, right machine

47
7.1.6 Entering negative dimensions

In certain circumstances or unusual machine configurations, negative dimensions may
also be entered where needed, such as coupling center-to-front foot (right machine)
when this foot is behind the coupling center, or coupling center to sensor if the sensor
is mounted on the coupling such that the sensor distance marking is infront of the
coupling as shown in the diagrams 1a and 1b below.
Spacer shaft
If the spool piece of a spacer coupling is removed, and offset support posts used to
clear any radial obstructions, the situation illustrated in diagram 2 below could occur.
1a
In the configuration shown,

the dimension coupling
center-to-sensor has a
negative value.
1b
48
2
B
In the case shown, B>A
A and C>A. This spacer shaft
situation is effectively
handled by “ROTALIGN
smart EX edition”.
Spacer removed
C
7.2 Machine set-up
All machine elements may be accessed within the dimensions screen using the
navigation keys.
Pressing q while in the dimensions screen reveals the menu items shown in the
next screen.
The expanded sub-menu

with the items ‘Horizontal
train’ and ‘Vertical train’
appears by pressing 7.
The required orientation
is selected by pressing
the appropriate shortcut
49
key. Alternatively use
f/g to highlight
the required menu item,
shifting between the
two panes using h/i.
Confirm selection by
The menu items are accessed by highlighting the respective item using f or g
pressing e.
then pressing e to confirm selection. Alternatively, press the respective shortcut key.
‘Resume last file’ opens file last saved before system was switched off
‘New file’ used to create a new measurement file
‘Soft foot measurement’ prompts the measurement of soft foot
‘Pipe strain wizard’ opens the wizard
‘Add last machine’ is used to add a machine to the current train. (The added
element appears on the right side of the train. Note that if the machine train has
three or more machines, the context menu item ‘Delete machine will be included
within the listed menu items.)
‘Train orientation’ is used to select either a vertical or horizontal machine train

orientation. For instance, you may wish to select ‘Vertical train’ for some flange-
mounted machines.
‘Change to OPTALIGN smart’ is used to allow measurement using the OPTALIGN
smart intrinsically safe transducer and reflector
7.2.1 Machine properties

With the machine highlighted, pressing e reveals the machine parameters that can
be edited.
Parameters that can be edited for stationary machines include: fixation, flange
position, type of machine and machine name.
To choose type of machine to be displayed, using f/g highlight ‘Choose

50
machine type’ then press e to confirm selection. The ‘Machine selection’ pane
opens.
Alternatively press 8 with

the context menu displayed.
The machine selection pane
appears.
Use f/g to scroll through the available machine type graphics.

If you need to change the orientation of the machine graphic use i/h.
If a machine is defined as moveable, the parameters that can be edited include:

fixation, flange position, thermal growth values, type of machine and name.
Soft foot measurement can

also be carried out from this
screen. 51
To edit the machine name, use f/g to highlight ‘Enter name’ from the
previous screen. Confirm selection by pressing e. The editing box appears and the
machine name may be edited.
Alternatively press 0 with

The editing box appears.
Use the data entry keys to edit the machine name.
Thermal growth values can be entered only when the machine is defined as moveable.
To enter thermal growth values, highlight ‘Thermal Growth’ using either f or
g.
Alternatively, access the

‘Thermal growth’ screen
directly by pressing the
shortcut key 7 with the
52
Press e. The “Thermal growth” screen appears.

Use the navigation keys to highlight the ‘feet pair’ where thermal growth is to be
entered. The editing box appears when any data entry key is pressed. Use the data
entry keys to enter the thermal growth value in the vertical orientation, cycling
through the feet pairs using the navigation keys.
To enter values in the horizontal orientation, press q while in the “Thermal growth”
screen. The context menu as shown below appears.

horizontal thermal growth
view directly by pressing the
shortcut key 4 with the
53
Use f/g to highlight ‘Horizontal thermal growth’ then press e to confirm

selection. The horizontal thermal growth view opens. Now proceed to enter values as
described for vertical orientation previously.
The editing box may also Carefully observe sign

be opened by highlight- convention (+ and -) when
ing a foot value using entering thermal growth
the navigation keys then values. Thermal growth
pressing e. values are NOT a target;
instead they represent the
amount and direction of
the anticipated movement
that the machine will
undergo when put in
operation.
Press ß after entering all values.
To disenable thermal growth values, use the navigation keys to highlight the green
tick. With the green check mark highlighted, press e. This disenables thermal
growth.
Alternatively, press q while in the ‘Thermal growth’ screen. The context menu
appears.
Alternatively use
f/g to highlight
‘Thermal growth’ then use
h to switch to the next
pane. Highlight ‘Disable’
54
using f/g then
confirm disenabling values
by pressing e.
Press 1 followed by 2 to disenable thermal growth values.

Thermal growth values

may be enabled from the
opposite screen once again
by pressing e.
7.2.2 Thermal growth 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 machine’s
thermal growth.
“ROTALIGN smart EX edition” may be used to calculate thermal growth compensa-
tion if no other values are available. Thermal growth is calculated from the material
characteristics, expected temperature difference and height of the shaft centerline
above the shim plane.
Thermal growth is calculated as follows:

Access the “Thermal growth” screen to the machine whose thermal growth
requires calculating as described previously.
Press q while on the screen. The context menu appears. Use f/g to 55
select ‘Thermal growth calculator’.
Press e. The thermal growth calculator pane appears.
Alternatively, the thermal

growth calculator pane
may be accessed directly
from the previous screen by
pressing the shortcut key
7 with the context menu
displayed.
Use the navigation keys to highlight the ‘Material’ information box then press
e to select type of material using the drop down menu that appears.
56
Confirm selection by pressing e.

Use the navigation keys to highlight the respective value boxes and enter directly,
the ambient temperature, the machine running temperature and the distance
from machine base to the shaft centerline using the data entry keys.
In the example opposite, the

motor material is cast iron,
the ambient temperature is
25°C, the machine running
temperature is 120° C
and the distance from the
bottom of the turbine feet
to the shaft centerline is 70
cm. This gives a growth of
0.71 mm.
7.2.3 Coupling properties

Coupling properties are entered and edited in the same manner as machine properties.
Use the navigation keys to highlight the coupling.
57
With the coupling highlighted, pressing e reveals the coupling parameters that can
be edited.
The menu may also be

used to reset the coupling
settings to default, i.e rpm is
1500, coupling diameter is
100 mm and the tolerance
table is based on 50 Hz.
Coupling parameters that can be edited include: coupling targets, user defined
tolerance values, type of coupling [types available are short flex, cardan and spacer
shaft] and sensor type option.
To enter coupling target values, press 1 with the menu displayed. Alternatively,
highlight ‘Targets’ using either f or g then press e. The “Coupling targets”
screen appears.
The editing box may also Carefully observe sign

be opened by highlight- convention (+ and -)
ing a value position using when entering target
the navigation keys then values. Target values
pressing e. are NOT the anticipated
thermal growth values;
instead they represent the
amount and direction of
the desired misalignment
to be set at the coupling
to compensate for the
anticipated movement
Use the navigation keys to highlight respective gap/offset to be entered. Enter the machine will undergo
coupling target value directly using the data entry keys. The editing box appears when when put in operation.
any data entry key is pressed. Confirm entry by pressing either e or ß.
To select type of coupling, simply press the corresponding shortcut key with the menu
displayed. Alternatively, highlight type of coupling required from the menu using
58 f / g.
Pressing 5 sets the

coupling as a spacer shaft.
The option ‘short flex’ does
not appear under the menu
items as it is the current
setting. If the current
setting was either ‘spacer’
or ‘cardan’, the item ‘short
flex’ would appear in the
menu.
Press e to confirm selection.

Type of coupling selected

is cardan
If using a spacer shaft, “ROTALIGN smart EX edition” provides the user with the
opportunity to display results in the following terms:
› projected shaft offset at left and right coupling flex plane
› gap difference of left coupling and right coupling of spacer shaft
› gap difference and projected offset at left coupling of spacer shaft
› gap difference and projected offset at right coupling of spacer shaft
To select any one of the above spacer shaft results format, use the configuration menu
item ‘Shaft settings’.
59
It may be necessary to specify individual tolerances. This is carried out using the menu
item ‘Tolerances’.
The coupling parameters

context menu is displayed
by pressing e with the
coupling highlighted.
To enter user defined tolerance values, Use either f or g to highlight

‘Tolerances’ then press e. The “User defined tolerances” screen appears.
Alternatively, access the In this example, the

‘User defined tolerances’ active tolerances are
screen by pressing 3 the user defined values.
while the coupling The ‘user’ button in the
properties context menu is lower frame is yellow. The
displayed. system tolerance table
is deactivated as can be
The ‘user’ button seen from the grayed
60
out smileys in the upper
frame.
Use the navigation keys to highlight gap or offset. Enter user defined tolerance value
directly using the data entry keys. The editing box appears when any data entry key is
pressed. Confirm entry by pressing either e or ß.
The values entered above are independent of rpm. When these values are enabled,
that is when the ‘user’ button in the bottom frame is yellow, they override the system
tolerance table.
Alternatively, the user defined tolerances may be deactivated by exiting the user
defined tolerances frame. This automatically enables the system tolerance table and
the smileys in the upper frame revert to yellow.
Press ß to exit the “User defined tolerances” screen.
Note that the tolerance screen toggles between “Tolerance table” and “User
defined tolerances”. Note
The tolerance screen context menu items may be used to deactivate the system
tolerance values, and toggle between the system tolerance values and user defined
tolerances.
61
7.2.4 Entering coupling target values as dial indicator readings

Coupling target values given in terms of dial indicator readings can be entered into
“ROTALIGN smart EX edition” for conversion to gap and offset. If the function
coupling targets is enabled, the converted values are automatically taken into account
when determining the alignment condition. To enter dial indicator measurements
proceed by pressing q while in the “Coupling targets” screen.
The “Coupling targets”

screen is accessed as
described on page 57.
When the context menu appears, press 2 to display the “Dial gauge set-
up”screen.
Note that a hint to set up the dial gauge configuration will appear followed by
the “Dial gauge set-up” screen.

Note
62 The dial gauge configura-

tion is set at the header.
Use the navigation keys
to highlight the header
then cycle through the
various configurations by
pressing e with header
highlighted.
Use the navigation keys to exit the header and cycle through the required dimensions.
Enter the required dimensions.
Press ß to access the ‘Targets as dial gauge values’ display. Enter the dial indicator
values in the respective value boxes.
63
Press ß to display the target values, including any bracket sag amounts entered in
terms of gap and offset.
7.3 Laser beam adjustment
After entering all dimensions, press m. The laser and sensor need to be adjusted so
that the laser beam strikes the sensor.
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 sensor dust cap on.
Do not stare into the laser beam!
2. If the laser and sensor have been roughly positioned to each other during
mounting (see section 4, page 44 – ‘mounting laser and sensor’ ), the laser beam
should strike the sensor dust cap. If the beam be so far off target that it misses
the sensor completely, hold a sheet of paper in front of the sensor to locate the
beam and readjust it onto the sensor as follows:
3. Reposition the components until the laser beam strikes the sensor cap:
vertically: loosen the locking knobs and adjust the height.
horizontally: loosen the bracket and turn the laser and/or sensor brackets into
line with one another.
4. Use the adjustment wheels on the laser to center the laser beam on the sensor
cap, then remove the cap.
The adjustment tube ALI 3.608 can be very helpful when misalignment is great,
especially over short separations.
It is highly recommended
that before mounting
64
1 Laser 2 3 the laser on its bracket,
both yellow adjustment
ON/OFF switch thumbwheels be brought
to the approximate center
of their travel range. This
will ensure that the beam
vertical
is emitted from the laser
4 as straight as possible
and not at an angle.
Also make sure both
brackets are rotationally
aligned to each other.
horizontal
These precautions will
Sensor greatly facilitate the beam
adjustment process.
Center the laser beam.

Red
‘Laser OFF’ displayed when
laser beam is out of range – Green
red LED is steady and green
LED is off.
‘Laser END’ displayed when
laser beam is at the edge of
range – both LEDs blinking
fast
Laser OK / centered when
beam is centred – red LED
is off and green LED blinks
slowly
Use the on screen hints to center the laser beam on the position detector. To ensure
that the laser beam is not only centered but also reasonably perpendicular, the
“Measurement” screen menu item ‘XY view’ may be used to check the location of
the beam on both position detectors. Full description of the XY view is on page 113.
65
The beam does not have to be exactly at the center of the crosshair, as this will

not affect measurement accuracy. However, maximum range for measurement is
available when the beam is well centered.
Note
Once centered, the sensor and laser must not be touched, as any movement
during measurement will be interpreted as misalignment. These components may
however be moved when extending the measurement range (see ‘Alignment
options’ on page 108).
8. Take 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 7.
Measurement mode Application
Continuous sweep Standard machines
Multipoint Uncoupled shafts, nonrotatable shafts, sleeve

measurement bearings, white metal bearings, journal (radial)
bearings, shafts that are hard to turn, shafts with
herky-jerky rotation, situations with long spans
or severe misalignment that will readily cause the
beam to fall out of range
Static measurement Vertical machines (four feet or flange mounted)
Pass mode Uncoupled shafts, nonrotatable shafts
When the laser beam is centered such that the dot on the display screen is at the
Remember not to touch
center of the crosshair, the blue computer LED lights up. Start measurement by
mounted components!
turning the shafts or press e to initiate the continuous sweep measure mode.
It is advised to turn shafts
Rotate the shafts a full turn or as far as possible.
66 in the same direction as
the machine normally
rotates, in case the shafts
shift from their normal
seating in the bearings.
You may begin
measurement by turning
the shafts even if the
beam is not centered
exactly at the center of
the crosshair.
9. Results
Results are obtained after rotating the shaft through as wide an angle as possible. As
the shaft is rotated, the covered arc changes colour from red to yellow and finally to
green. A red sector signifies that the covered angle is insufficient for accurate results.
Results can be obtained when the sector is yellow, but it is recommended that the
shafts be rotated until the arc is green. If you press e to finish measurement and
collect data, the following screen appears.
The black lines in the

rotational arc indicate the
positions where readings
have been taken. In case
of vibration, switch to
multipoint measure mode
and a higher averaging
(refer to chapter 7).
Alternatively, view alignment results directly by pressing k once measurement is

completed.
9.1 Coupling results and feet positions

The following display shows the measured alignment condition along with numerical
values for the coupling and actual machine feet positions. 67
This complete alignment

condition screen appears
only when the option
‘All-in-one results’ is
activated in the ‘Shaft
settings’ configuration
menu. If not activated then
the screen displays only
coupling results.
Coupling results are given in the form of gap and offset values in both vertical and
horizontal directions. The true gap being the difference in gap between the coupling
faces top to bottom (vertical) or side to side (horizontal) at the diameter that was
entered. Offset on the other hand is the distance between two lines at the transmis-
sion plane of the coupling.
9.2 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 is upwards or away from
viewer. Negative values indicate that machine is downwards or towards the viewer.
If all four coupling values are within tolerance, you do not need to align the
machines.
Note
If no in-house standards or specifications from the coupling or machine manufacturer

are available, the computer LED system and the smiley provides a tolerance check
based on standard industry norms. If the measured alignment falls within accept-
able tolerance, the green LED lights up. The blue LED lights up when the measured
alignment falls within excellent tolerance. The red LED lights up when alignment is out
of tolerance. In this case, the machines must be aligned.
If the coupling results show that misalignment exceeds the tolerance, then the
machine must be realigned by shimming vertically and repositioning the machine
68 horizontally. The different views may be accessed by pressing k/f/g.
On the following two

screens, the “Shaft settings”
screen menu item ‘Tolerance
envelopes’ is activated on.
If not activated on then the
tolerance envelopes will not
be displayed.
9.3 Multiple feet results

If measuring a six-foot machine, it is possible to determine the correction value of the
middle pair of feet. Press q when in feet results.
Alternatively, press 4
with the context menu
displayed. The multiple feet
calculator pane opens.
69
Use f/g to highlight the context menu item ‘Multiple feet calculator’.
Confirm selection by pressing e. The multiple feet calculator pane opens.
With the multiple feet

calculator pane open,
enter the dimension
between the first and
middle pairs of feet. The
foot correction value at
the middle feet appears
in the box just below the
foot correction value for
entered dimension.
middle pair of feet
9.4 Results table

The results table lists up to 15 coupling result entries for currently selected set of
machines. The entries are in reverse chronological order with the most recent result
appearing first on the list.
q while
The measurement table is accessed through the “Results” screen. Press
in results. Use f/g to highlight ‘Results table’ from the context menu that
appears.
Alternatively, the results

table can be accessed
directly by pressing 3
while the context menu is
displayed.
Press e to confirm selection. The results table is displayed.
70
Use f/g to scroll though the coupling results entries. Multiple results 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:
1. Use f/g to highlight a results set for inclusion in the average.
2. Press e to select the results set. A check mark appears next to the results
position indicating that the results set has been included in calculating the
average.
3. Repeat steps 1 and 2 for all other results sets to be included.

To remove a results set from the average calculation, highlight the results set
using f/g then press e. The check mark next to the results position
disappears indicating that the results set is not included in calculating the Note
average.
It is not possible to average results sets separated by a Move action.
The measurement details for each single results set can be displayed using the results
table context menu. With any one given results set highlighted, press q then use
f/g to highlight the context menu item ‘Measurement details.
71
With ‘Measurement details’ highlighted, press e to confirm selection.
The measurement details

shown here are from a
Move results set. These
details can be accessed
with the results table
Measurement details can
also be displayed from
the results table directly
by pressing i with
the desired results set
highlighted.
The measurement details

shown here have ensued
from a Continous Sweep
results set.
Note that the standard
deviation is also displayed.
9.5 Alignment quality

The ‘smiley’ symbol by the coupling results display indicates the degree to which
the measured alignment condition meets tolerances. The smiley face depicts either
alignment within tolerance or out of tolerance and appears only when tolerances
have been enabled (see ‘coupling properties in section 7.2.3).
Within excellent tolerance
Within acceptable tolerance
Out of tolerance
72
The computer LED system provides additional information on the tolerance status.

Tolerance Smiley Lit LED
Within tolerance Happy face Blue

Note
Within tolerance OK Green
Out of tolerance Sad face Amber
Grossly misaligned Sad face Red
The ‘smiley’ TAKES INTO ACCOUNT any targets and thermal growth values
which you may have entered – see pages 52 – 58.

Note
9.6 Tolerance table

It is possible to display the suggested active PRÜFTECHNIK Alignment Systems
tolerance table.
These suggested alignment tolerances are general values based upon experi-
ence 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

CAUTION
(tighter) values.
The tolerance table is accessed from the “Results” screen. Press q to display the
context menu.
With the context menu open, press 5 to open the tolerance table. Alternatively,
highlight ‘Tolerance table’ using either f or g then press e. The “Tolerance
table” screen appears. 73
The tolerance table values are rpm dependent. Changing the rpm results in the cor-
responding gap/offset tolerance values. Use the navigation key to highlight the rpm
box. With the box highlighted, use the data entry keys and enter the required rpm
then confirm entry pressing e.
The new rpm is now applied in the machine set-up.

Other menu items related to tolerances may be accessed via the context menu which
is opened by pressing q from the “Tolerance table” screen.
74
The context menu item ‘User tolerance’ is used to set user defined gap and
offset tolerance values. When these defined values are active, the system
tolerance table is disenabled. The menu item ‘Disable tolerance’/’Enable
tolerance’ is the used to enable and disenable both system and user defined
tolerances.
The tolerance table can be printed directly to the configured printer or saved to
a memory stick (aka jumpdrive) as a pdf if the printer configuration is set to pdf
file. In this case, use is made of the adapter box ALI 12.500.
10. Align machine

Machines can be aligned using the given foot results by proceeding as described
below. Remember, if alignment is in tolerance (indicated by a happy smiley
symbol and the blue or green system computer LED), there is NO need to align Note
the machines.
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, but the recommended procedure is as follows:
10.1 Shim first
It is recommended to perform vertical corrections first, since the horizontal

condition is easily affected by the process of loosening anchor bolts and inserting/
removing shims, whereas the vertical condition is less prone to being affected
Note
when performing horizontal moves. You may need to recheck soft foot before
proceeding.
10.1.1 Preparation and shimming

i) Prepare the machines for shimming by ensuring the following:
The foot bolts are clean, intact and removable.
Soft foot has been eliminated.
The feet have enough shims under them should lowering the machine be
necessary.
Good quality shims such as PERMABLOC, MYLAR or LAMIBLOC are available
75
from PRÜFTECHNIK Alignment Systems.
ii) Loosen foot bolts while trying to avoid moving the machine horizontally. If any
foot comes off the ground when loosened, suspect soft foot.
iii) Use the vertical foot position values to shim BOTH front and back feet as
required. Positive feet values indicate that the feet are high and therefore shims
should be removed, while negative feet values indicate that the feet are low and
suggest addition of shim thickness.
iv) Retighten and remeasure to verify vertical results and determine the exact
alignment condition.
Note that vertical shimming can also be carried out with the live vertical Move.
10.2.1 Horizontal and vertical live Move

Note
The ROTALIGN sensor technology allows Live Move corrections in both horizontal
and vertical directions concurrently with the sensor at any angular position.

Note
The alignment corrections involving shimming and the lateral positioning of the
machines can be followed in a real-time interactive display. From the results screen,
press q. The context menu appears.
76
Use f / g to highlight ‘Move’ then press e to confirm selection. If the laser

beam is centered proceed to carry out live Move in one direction (say horizontal Move
first) then in the other direction (say vertical shimming).
Alternatively, live Move may

be started directly from the
previous screen by pressing
the shortcut key 1 with
If however the laser beam is not centered, use the available on-screen hints to
center the laser beam. You could also use the ‘Move’ screen context menu item
‘XY view’ for this adjustment. Live Move resumes automatically once the laser
Note
beam has been centered.
10.2.2 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 moved towards viewer, while negative feet values
suggest the moving the machine feet away from viewer.
iii) Move the machine feet in the direction of the yellow arrows, keeping an eye
on the smiley on the display screen. The arrows change with the movements
automatically. Watch the display screen carefully to ensure that machine end and
direction moved are correct. The smiley on the display screen and the computer 77
LEDs also give an indication of the alignment condition as the machine is moved.
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. CAUTION
10.2.3 Shimming using the live Move

After making the lateral corrections, you may want to use the live Move function to
carry out vertical shimming corrections.
i) Press q then use f/g to select ‘Change view’ followed by ‘Vertical’.
ii) Confirm selection by pressing e and proceed to carry out live Move in the
vertical direction.
78
iii) Use the vertical foot correction values to shim BOTH front and back feet as
required. Positive feet values indicate that the feet are high and therefore shims
should be removed, while negative feet values indicate that the feet are low and
suggest addition of shim thickness.
iv) If the smiley returns a happy face or an OK symbol, the alignment condition is
within tolerance.
v) Tighten anchor bolts and to proceed to verify alignment condition after Move.
vi) Press q then use f/g to highlight ‘Stop’.
79
vii) Confirm selection by pressing e.

viii) With the option to re-measure highlighted, press e to confirm selection. The
measurement mode is initialized. Recheck alignment by taking another set of
measurements and viewing results. If they are in tolerance, then the machines
are aligned.
10.3 Saving data and printing

(See section 11 on page 82.)
10.4. Finish alignment

Switch off the computer, remove the components from the shafts and store them in
the case.
Replace guards before you switch the machine back on.

WARNING
80 10.5 Points to observe during the live Move
10.5.1 Have shafts accidentally moved (rotated)?
The shafts, sensor and laser MUST remain steady during the entire Move procedure.
Should the shaft move from the set position while in live Move, the angle adjustment
window comes up indicating the angle to which the shaft has rotated. The shafts
must be rotated back into the narrow green sector.
Live move resumes automatically when the shafts are rotated back into this
sector.
Note
10.5.2 END or OFF? The ‘Extend’ function

If END or OFF appears on the screen during live Move, then the laser beam has drifted
out of detection range due to great misalignment or long beam travel. In this case, the
measurement range can be extended as described on page 108.
10.5.3 Soft foot

If the machine suffers from excessive soft foot, the live Move function may be
hampered by the fact that the machine changes its position on its own every time
the bolts are loosened and tightened. Correct this before aligning. (See page 91 for
details.)
10.5.4 If poor repeatability is experienced 81

Possible causes include:
› Incorrect or loose bracket mounting

› Significant shaft play or coupling backlash
› Soft foot can cause positioning errors that make repeat measurement
necessary Note
› Loose anchor bolts
› Yellow knobs on sensor or laser loose
› Temperature changing: machines recently shut down?
› Uneven shaft rotation
› Shaft deflections from coupling strain
11. Saving data and printing
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. Full file names with up to 32 alphanumeric characters are
possible.
The length of the file name is limited depending on the typeface used.
11.1 To save a file

The current measurement file can be saved at any time. To save the file, press q
twice. Highlight ‘Save file’ using f/g.
Alternatively, pressq
twice followed by 2 to
open the “Save file” dialog
window directly.
Press e to confirm selection. The editing box appears.

82
When entering names that

contain both upper and lower
case characters as well as
numerals, use o to cycle
through the three options.
Press and hold down o while
observing the status indicator at
the top left corner of the editing
box. This displays the type of
character to be entered.
Empty spaces are entered by
pressing 0.
Use the data entry keys to enter the file name and confirm entry by pressing either
ß or e.
Saving and printing
11.2 Printing reports

Using the PRÜFTECHNIK Alignment freeware ALIGNMENT REPORTER, reports may be
saved on a PC then printed off any Windows printer or networked printer without
disconnecting or reconfiguring the printer. ALIGNMENT REPORTER is available on
the ALIGNMENT REPORTER CD ALI 13.701 CD or may be downloaded from the
ALIGNMENT REPORTER website – www.alignment-reporter.com.
For details on using ALIGNMENT REPORTER please refer to the software’s online
help which is also available in hardcopy. Note
Reports can also be printed directly from the system computer to a printer. For ALI
12.200 EX, printing is carried using the USB A/B cable ALI 12.504-2 connected via the
adapter box ALI 12.500.
Printing must take place outside the hazardous area.

WARNING
Adapter box ALI 12.500
83
Intrinsically safe system
Adapter box cable computer ALI 12.200 EX
USB A/B cable ALI 12.504-2

connected to a printer
To print the current measurement report, press q twice, then use f/g to
highlight ‘Print’.
Alternatively, pressq
twice followed by 6 to
open the “Print report ”
dialog window directly.
Press e to confirm selection. The “Print report” screen appears.
84
The system provides the option of printing reports in four different formats. Use
f/g to highlight the desired format and then press e to print the selected
report.
11.3 Configuring printer

If unable to print the measurement report, the printer settings must be verified.
This can be carried out from the “Print report” screen. Press q and use either
f/g to highlight ‘Printer configuration’.
Press e to confirm selection. The “Printer configuration” screen appears and the
printing settings are made.
Alternatively, the “Printer configuration” screen can be accessed at any time as

described in Chapter 4, ‘Configuration and data management’.
11.4 Available printing options

The “Printer configuration” screen shows the options that can be selected.
85
Use either f/g to highlight the printer setting to be changed. The options
that are available are displayed by pressing e.
Use f/g to scroll

through the available
printers. Highlight a printer
and press e to confirm
selection.
This option can also be used to save measurement files directly as a pdf. Use
f/g/0 to select the topmost printer type ‘Pdf file’.
After highlighting ‘Pdf

file’ press e to save the
selected measurement file
as a pdf file.
86
Use f/g to scroll

through the available paper
sizes. Highlight the required
paper size and press e to
confirm selection.
Use f/g to
change the page orientation
between ‘Portrait’ for
a vertical layout and
‘Landscape’ for a horizontal
layout. Confirm selection by
pressing e.
Use f/g to
select the colour in which
the report will be printed.
Selecting ‘Color’ results in
full colour reports, while
‘GrayScale’ results in black
and white reports.
87
88
Quick check
Chapter 6: Quick check measurement

At some point, it may be necessary to check the alignment of a machine set that has
been running long enough to reach its ‘steady state’ (‘hot’) operating condition. In
that case, the system can be used to take quick alignment readings in a matter of a
few minutes after the machines are shut off. The following procedure saves time by
allowing you to begin measurement immediately after switching on the computer, i.e.
without entering machine dimensions first.
1. As soon as the shafts have stopped rotating, lock out machines and observe all
safety precautions, then mount the components, and connect the sensor to the
system computer as described on page 44 [‘Mount laser and sensor’].
2. Switch the computer on and press m. If the laser beam has been centered on
the detector, turn the shafts in their normal direction of operation by at least
60°.
89
3. Press e to finish measurement. The following hint appears.
After measurement is
finished, pressing k skips
the hint screen landing
directly into the missing
dimensions screen.
ROTALIGN smart handbook
4. Proceed by pressing e. The screen with dimensions missing appears. Enter the
required dimensions.
Missing dimensions are

entered using the data
entry keys and confirmed by
pressing e.
5. Once all dimensions have been entered, the results screen appears.
The alignment results

displayed depend on
whether the shaft setting
‘All-in-one results’ has
been activated. The screen
opposite shows both the
coupling and feet results.
Use k/f/g to
cycle through the different
90
results views.
If however, the option ‘All-in-one results’ has not been activated in the ‘Shaft
settings’ configuration menu, only the sensor to coupling center dimension
needs to be entered to display coupling results.
Soft foot
Soft foot
SOFT FOOT is the condition of machine frame distortion. Any cause that results in
machine frame distortion when the machine is anchored to its foundation is a soft
foot. Some of the principal causes are:
› 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.
Soft foot should be checked before aligning the shafts. This can be done quickly and
conveniently with the aid of the instrument’s soft foot function. With the sensor and
laser mounted on the shaft at any angular position, the system is able to sense any
machine movement when the machine bolts are loosened individually. By entering the
machine dimensions, “ROTALIGN smart EX edition” is able to calculate, from shaft
movement, by how much each foot has moved as it is loosened.
91
Parallel soft foot Angular soft foot
One or more feet are The base of the foot is at
too short or too long. an angle to its foundation
This usually results in the and they are only partly in
machine rocking on the contact. In this case, suspect
longer feet. This is corrected foot is checked with a feeler
by shimming the shorter gauge and corrected by
feet. building a custom ‘shim
wedge’ or machining the
underside of the 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 checked is/are assumed to have four feet in an approxi-

mately square formation. If the machine has six feet, it is advisable to leave the
middle feet loose and treat the machine as a four-footed machine. Soft foot is

Note
measured only on machine designated as movable.
1. Set up the system in the normal way as described in ‘Horizontal machine

alignment’ (pages 42-45), then switch on the laser. Adjust the beam onto center
of the sensor dust cap.
2. Remove the sensor dust cap.
3. Switch the computer on then enter machine dimensions.
4. Use the navigation keys to highlight machine whose feet are to be measured.
5. With the machine highlighted, press q. The context menu appears.
92
6. With the context menu displayed, press 3 to access ‘Soft foot’ screen. Alter-
natively, access the screen by using the navigation keys to highlight , then
pressing e to confirm selection. If the laser beam is centered, the following
screen appears.
Soft foot
7. Press e to continue with soft foot measurement ( proceed to step 7f). If

however, the laser beam is not centered, the following screen appears.
93
7a. Use the on-screen instructions to adjust the laser beam, or refer to ‘Laser beam
adjustment’ on page 64.
7b. The laser beam can also be centered using the XY view. Access the XY view
screen by pressing q while in the soft foot screen. The context menu appears.
The context menu item

‘Adjust laser’ may also
be used to prompt the
on-screen instructions.
With the context menu
displayed, press 3 to
show the laser adjustment
instructions. Alternatively,
use either f/g
to highlight ‘Adjust laser’,
then press e to confirm
selection.
7c. With context menu item ‘XY view’ highlighted, press e to access the XY view Full description of ‘XY
screen. View’ may be found on
page 113.
7d. 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.
94
7e. After centering the laser beam, press ß to return to the soft foot screen. Press
e to proceed with measurement.
If however, either of the two significant machine dimensions, ‘front foot-to-back

foot’ and ‘laser-to-coupling center’, are missing, the following hint appears.
Note
Soft foot
Use f/g to
highlight ‘Yes’, confirming
The dimensions screen
opens, and missing values
may be entered.
7f. After all required missing dimensions have been entered, the soft foot screen
opens automatically. Proceed with soft foot measurement.
8. Use the navigation keys to select the foot to be measured. Press e to confirm
foot selection. Loosen the corresponding anchor bolt.
95
9. The calculated distance that the foot has risen is shown on the screen. Press
e to store the value and retain it in the display. Retighten the bolt. The next
foot is highlighted automatically, or any desired foot can be selected using the
navigation keys.
10. Repeat this procedure for each foot. Cycle through using the navigation keys if
required.
The set soft foot tolerance

is 0.06 mm (0.002’). The
happy Smiley indicates that
the measured soft foot
is within tolerance and
shimming corrections are
not necessary.
With the four foot values, the shimming corrections can be determined. Note that
these values are saved in the file along with the dimensions, measurement and results,
and appear in the printed report.
96
Soft foot
Parallel soft foot correction

If two diagonal values are roughly equal and significantly higher than the other two,
parallel soft foot can be assumed as a first solution.
Angular soft foot correction

If one value is significantly higher than the others, then angular soft foot can be
suspected.
The ‘problem foot’ or machine frame is probably bent or distorted in some way. In
this case loosen the bolt and examine the foot more closely. Use a feeler gauge to
establish the variation of the gap and use these measurements to sketch the shape
and dimensions for a ‘stair stepped shim wedge’.
If the soft foot is purely ‘angular’ then the stepped shim will vary in thickness from
about zero to twice the value displayed by the computer.
Parallel soft foot

The machine is rocking on
two diagonal feet which
are longer than the other
two. In this example, the Angular soft foot
correction would be to The base of one or more
place a 0.89mm shim under feet is at an angle to the
foot ‘b‘ (the foot with the foundation and is only
largest gap) partly in contact.
97
a 0.18 0.89 b a 0.18 0.13 b
c 0.74 0.10 d c 0.76 0.10 d

Checking pipe strain

The effects of pipe strain on shaft alignment can be measured using “ROTALIGN
smart EX edition”. This feature is used to check for strain from external sources acting
on machines. The measured values are quantified in terms of offset and angularity.
The values are combined for both the vertical and horizontal directions. This check can
prove the existence of pipe strain on a pump or conduit strain on a motor.
An external stress on a machine frame usually results in machine frame distortion. It is
important to ascertain its existence and eliminate it. This check complements but does
not replace the soft foot function.
How the function works

After mounting the laser and sensor as usual, turn the system computer on. Enter all
necessary machine dimensions as usual. Press q while in the dimensions screen. The
context menu with the function ‘Pipe strain wizard’ (4) appears.
Alternatively, start the

wizard directly by pressing
displayed.
98
With the context menu displayed, use f/g to highlight ‘Pipe strain wizard’
then press e to confirm selection. The wizard starts.
The wizard opens always

with the ‘Next’ button
highlighted. Should this
not be the case, use the
navigation keys to highlight
‘Next’. The wizard may be
exited by highlighting the
‘Exit’ button and confirming
Soft foot
With the ‘Next’ button highlighted, press e to proceed.

If the components have not yet been mounted, ensure that they are properly
mounted and the sensor is connected to the system computer. You may refer to
the chapter ‘Horizontal machine alignment’ on page 42 - 45. Note
With the ‘Next’ button highlighted, press e to proceed with measurement. The
measurement screen appears.
If the laser beam is not

q
centered, press
followed by 2 to
proceed with laser beam
adjustment. Alterna-
tively use g/f 99
to highlight the context
menu item ‘Adjust laser’,
confirming selection
by pressing e. After
adjusting the laser
beam press e or
ß to proceed with
Rotate the shafts over a wide enough measurement range. When a wide enough
measurement.
measurement range is attained, the ‘Stop’ button appears.
With the ‘Stop’ button highlighted, press e to finish the first measurement. The
instruction to loosen pipe flange bolts then appears.
100
After loosening the pipe flange bolts, press e with the ‘Next’ button highlighted.
This prompts the start of the second measurement step.
Soft foot
Proceed to take measurements as described in first measurement steps previously.
Pipe strain results are automatically displayed after pressing e with the ‘Stop’
button highlighted.
Toggle between ‘Finish’ and

‘Print’ using the navigation
keys. Confirm required
option by pressing e.
101
The pipe strain measurement is documented in the file measurement report and may
also be saved as an individual pipe strain measurement report PDF file or printed
directly from the system computer. To save or print report, refer to the section ‘Saving
data and printing’ on page 82.
The measurement procedure and wizard instructions are dependent on the

measurement mode used. In all instances, a wide enough measurement range
has to be attained.

Note
102
Alignment options
Chapter 7: Dynamic alignment features
Measurement modes
In addition to the standard ‘Continuous Sweep mode’, “ROTALIGN smart EX

edition” EX also offers Multipoint, Static (0369) and Pass measurement modes.
The measurement modes are accessed via the measurement screen. Press m to
access the measurement screen. While in the “Measurement” screen, press q. Use
the navigation keys to select ‘Measurement mode’ -> ‘Multipoint’ (or ‘Static’ or ‘Pass’
or ‘Sweep’). The choice depends on the measurement mode required.
Alternatively, the required

measurement mode may
be selected directly by
pressing 3 followed by
the shortcut key to the
required mode, e.g 2 for
Multipoint measurement
mode.
Press e to confirm selection.
103
In this case, the selected
measurement mode,
Multipoint is now active.
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.
After centering the laser beam as described in ‘Laser beam adjustment’ on page 64,
press e to take the first measurement point. Rotate shafts in their normal direction
of operation from one measurement position to the next, pressing e to 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.
The measurement arc

turns from red to yellow to
green depending on the
number points taken and
the angle covered. A yellow
arc signifies that taken
measurements are sufficient
to obtain results; however,
it is recommended to obtain
a green arc for even greater
accuracy and quality of
readings.
After finishing measurement, press k to display results.
104 Static measurement

This measurement mode is used for uncoupled shafts, nonrotatable shafts and vertical
foot-mounted or flange-mounted machines.
turn the shafts 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 positions viewed from coupling towards laser emitter).
Position shaft as accurately as possible using either an external inclinometer, spirit
level or protractor.
Alignment options
Use the navigation keys to position the clock hour hand to the corresponding shaft
position.
Pressing the navigation

keys positions the clock
hour hand at the next 45°
position.
Press e to take the first measurement point. After point is taken, rotate shafts to the
next measurement position. Ensure shafts are accurately placed at the 45° position.
Use the navigation keys to move the clock hour hand on the display screen to the cor-
responding shaft position. Take next measurement point by pressing e.
If shaft rotation restrictions hinder the taking of measurement at particular shaft

positions, bypass these using the navigation keys.

Note
Measurements must be taken in at least three positions over 90°, but it is recommended
to take more measurements over a wider angle.
105
After finishing measurement, press k to display results.

Pass mode
Uncoupled or nonrotatable shafts (one or both) can best be measured in ‘pass’ mode,
where the laser is rotated past the sensor in several different rotational positions. The
laser and sensor can be mounted in a variety of ways depending on the alignment
situation.
press e to take the first measurement point, then rotate the sensor to the next
measurement point.
Rotate the laser slowly past the sensor. When the sensor takes a measurement at
its current position, the green LED on the front of its housing lights for about one
second.
Cover the laser aperture (i.e. with one hand) and rotate the sensor to the next
measurement position; repeat the procedure to take measurements in at least three
106 positions over at least 60° of rotation, but more measurements over a wider angle is
recommended.
Laser beam
Sensor
Adjust laser beam
Laser ‘passes’ sensor

(measurement)
Alignment options
After finishing measurement, press k to view results.
If only one shaft is nonrotatable while the other can be freely rotated, always
y

mount the sensor on the nonrotatable shaft (use the magnetic sliding bracket
ALI 2.230). Do NOT mount the laser emitter on the nonrotatable shaft, even if
this means setting up your laser and sensor opposite to the way you normally Note
would for alignment purposes. You can always invert the movable and stationary
machines by using the static feet utility in the results screen. Enter all dimensions
in accordance with your actual set-up, following the normal orientation of the
laser and sensor in the dimensions screen.
Magnetic sliding
107
bracket ALI 2.230
Uncoupled shafts:
Mount laser and sensor
Nonrotatable shaft(s):
using chain-type brackets
Mount sensor using
magnetic sliding bracket
(ALI 2.230).
Special measurement features
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.
The ‘extend’ option is available only in ‘multipoint’ and ‘static’ measurement

modes.
‘Laser END’ is displayed when the reflected beam misses the detector. This situ- Note
ation occurs when machines are severely misaligned, or when the beam travel is
long. Measurement is not taken when this message appears.
1. When measuring and ‘Laser End’ message appears, rotate the shafts backwards
until the laser beam re-enters the measurement range. The message ‘Laser
OK’ reappears on the display. Press q to access the ‘extend’ option. Use
g/f to highlight ‘InfiniRange’.

Infinirange screen directly
by pressing 2 with the
108
2. Press e to confirm selection. The program interrupts measurement and

switches to the beam adjustment screen. The current beam position is automati-
cally recorded and taken as the starting point for range extension.
Alignment options
CAUTION! Do not allow

shafts to turn during this
process.
3. Readjust the beam into the target circle using the yellow laser emitter
adjustment wheels.
109
4. On centering the laser dot, the blue system computer LED lights up. Press e.
The adjusted beam position is automatically recorded and taken as the end point
of the readjustment.
5. Continue measurement as before, rotating the shafts and pressing e to take

measurements at the desired positions.
The program includes the displacement of beam readjustment in its alignment cal-
culations.
Remeasuring
The possibility to remeasure is provided in all measurement modes. To remeasure, the
current measurement needs to be stopped. To stop a measurement, press q while
carrying out measurement. Use g/f to highlight ‘Stop’.
Alternatively, stop
measurement by pressing
displayed.

To start a new measurement, press q and use g/f to highlight ‘Start’.
110
Start measurement directly

by pressing 4.
A different measurement mode can also be selected under ‘Measurement mode’

before starting to remeasure.

Alignment options
Resume
“ROTALIGN smart EX edition” provides the possibility to turn off the instrument during
measurement and resume with the last file opened. On switching the instrument on,
the measurement file loaded is the one that was last opened, provided it had already
been saved. If you prefer to open a completely new file, press q followed by 2.
This auto-resume function ensures that the measurement file last selected, when
the instrument switches itself off due to the power management function ‘power
scheme’ (see configuration on page 28), remains the active file when the instrument
is switched on again.
Averaging
In certain industrial conditions, it may be necessary to increase the number of measure-
ments to be averaged when taking readings to attain the desired accuracy. Particular
cases include applications with increased machinery vibration. An increased averaging 111
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 are set via the measurement screen. Press q while in the measurement
screen. Use g/f to highlight ‘Averaging’.

averaging screen directly
by pressing 6 while the
context menu is displayed.
112
The average setting can be changed from a minimum averaging of 0.4 seconds to a
maximum averaging of 12.81 seconds.
Averaging is possible only in Multipoint and Static measurement modes. The

averaging setting that is selected will also be active in soft foot and Move. Should
high averaging be selected, patience must be exercised during Move to allow
“ROTALIGN smart EX edition” enough time to ‘catch-up’ as the machine is

Note
moved. In this case, each reading that must be calculated to update the graphic
display will take a longer time. Averaging cannot be changed once a measure-
ment has been started.
Alignment options
XY View
Before measurement begins, the laser beam must be adjusted such that it strikes
the detector surface. The beam should strike the detector as close to the center as
possible. To facilitate adjustment, the height of the sensor and the laser should be
aligned, and the brackets rotationally aligned.
The option ‘XY View’ can be activated to help meet the requirement mentioned
above.
To access the ‘XY View’, press q while in the measurement screen. Use g/f
to highlight ‘XY View’.
Alternatively, access the XY

view directly by pressing
5 while the context
menu is displayed.
Confirm selection by pressing e. The laser beam position on the two detector
planes is displayed.
Displayed are the absolute

X,Y coordinates of the laser 113
beam on the two detector
surfaces, the angle at which
the sensor is currently
positioned on the shaft and
the sensor temperature.
Additional ‘XY View’ capabilities include the setting of the XY coordinates as a

reference value. To access this option, press q while in the “XY View” screen above.
Relative coordinates may be

accessed directly pressing
3 while the context
menu is displayed.
Use g/f to highlight ‘Relative coordinates’. Pressing e to confirm selection

sets the current laser dot position at 0,0 on both detectors.
The adjusted beam position

is set to ‘0,0‘ on both
detectors to serve as a
reference.
Press e to toggle
between the reference and
the absolute values. This
can also be done via the
‘XY View’ context menu.
114
If the laser beam dot is adjusted while in the “Relative mode” screen, it traces a path
showing the laser dot movement.
The coordinates to the new

laser dot position are
‘-4.4, 0.1’ and ‘-4.3, 0.1.
Machine train alignment
Chapter 8: Special alignment 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 six machines coupled together)
Cardan drive machines
Flanged machines (mounted vertically or horizontally)
How to align machinery trains

The following step-by-step approach is recommended for multi-element trains ( a
maximum of six machines).
› a. Measure alignment at each coupling
› b. Display results and optimize corrections (by defining ‘stationary’ machine
feet)
› c. Align two machines (remount laser and sensor if necessary)
› d. Recheck alignment results
› e. Align the next two machines in the train and repeat alignment check
› f. Repeat step (e) until all machines in the train have been aligned
Machine train set-up

Machine train set-up resembles the set-up described on pages 42-45 and will therefore
be outlined here only briefly.
› While in dimensions screen, use the navigation keys to highlight either 115
machine then press q. The context menu with the menu item ‘Add last
machine’ appears. .
› Use f/g to highlight “Add last machine” and confirm selection by

pressing e. The added machine appears on the right end of the train.
with the dimensions
context menu displayed
[see previous screen] to
automatically add machine
to the right end of the train.
› Configure the machine train as appropriate.
The train elements

appearing on the screen are
shown highlighted on the
train icon on the top right
of the display. Pressing h
or i long enough moves
the view of the train to the
right or left respectively.
116
Use h/i to highlight

machine to be edited.
Pressing e reveals the
corresponding submenu.
Measurement
› Use h/i to select the coupling to be measured.
› Ensure the laser is mounted on the left side of the selected coupling.
› Remove the dust cap from the laser and switch it on. Leave the sensor dust
cap on.
› Press m and adjust the beam onto the sensor (refer to section 7.3 ‘Laser
beam adjustment’ on page 64).
› Proceed to carry out measurement as described in section 8 ‘Take measure-
ments’ in chapter 5, observing the requirements for valid measurement
– shafts must be turned by at least 60°, a minimum of 3 measurement points
to be taken.
In this example, coupling

1 is measured using the
multipoint measurement
mode. Measurement is
stopped by pressing q
followed by 3 when the
context menu appears
› Press e to stop measurement.

If the measurement mode used is not continuous sweep, measurement is stopped by
pressing q followed by 3, as shown in the following screen. 117
Pressing 3 when the

context menu appears stops
measurement.
› Switch the laser off and mount the laser and sensor across the next coupling.
› While in the “Measurement” screen, press h/i long enough to move to the
next coupling to be measured.
In this example, coupling

2 is measured using the
continuous sweep measure-
ment mode. In this case,
measurement is stopped by
pressing e. Alternatively,
press q followed by 3
when the context menu
appears

Please make sure when moving the laser and sensor to each coupling that the
dimension from coupling center to sensor is entered correctly in the dimensions
screen. Note
Always make sure the coupling you are measuring is the one actually highlighted
in the machine train.
› Repeat the measurement procedure as described previously until measure-

ments have been taken across all couplings.
Evaluating results
118 Press k to view the alignment results at the individual couplings. Cycle through all
available results screens using f/g/k.
Horizontal and vertical feet

and coupling values for
machines B and C
Vertical feet and coupling

values at the coupling
position between machines
B and C
Horizontal feet and coupling

B and C
Entire machine train

overview with vertical
119
feet and coupling values
between machines B and C

overview with horizontal
between machines B and C
Press and hold i/h to jump to the next coupling in the train.
Jumping from one coupling position to the next is not possible from the results
overview screen and is carried out from results screen depicting two machines
only.

Note

A and B
120

A and B

between machines A and B

between machines A and B
Horizontal and vertical feet

and coupling values for
121
machines B and C
Move corrections
After deciding on which pair of machines to move in a train, you may need to reinstall
and readjust the laser and sensor across the chosen coupling. Be sure to install the
sensor at exactly the same location on the shaft or coupling as previously.
Correction of misalignment may be carried out using the live move function. While in
results screen, highlight the machines to be moved then press q. The context menu
appears. Use f/g to highlight ‘Move’.
Confirm selection by pressing e. If the laser beam is centered, and either machine
is designated stationary, Live Move starts automatically.
Live Move is also accessed

122 with the results screen
If however, the pair of machines selected are both designated movable, then a hint
appears on the display requesting the designation of only one machine as movable.
If the laser beam has not

been centered, the laser
adjustment guide appears
on the screen. Use it to
center the laser beam
Use f/g to highlight the machine to be moved, then press e to confirm

selection. If the laser beam is centered, Live Move starts automatically.
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

CAUTION
moving machines.
123
Move the machines until the alignment condition is within the specified tolerance
which is indicated by the smiley and the system computer alignment condition LEDs.
Tighten the anchor bolts and then press q to conclude the Move procedure. The
Live Move context menu appears. Use f/g to highlight ‘Stop’.
Press e to finish Live Move. A hint appears on the display requesting whether to
repeat move or exit and remeasure.
Use f/g to
highlight action to be
taken. Press e to confirm
selection.
124
As the true position of shaft rotation axes can only be determined by rotating the
shafts during measurement, it is not possible to exit live move without carrying
out another measurement.

Note
Remeasure to confirm the alignment condition. If the smiley returns a happy face, the
alignment condition is within tolerance and you may press e to save measurement
results.
This section describes the aligning of cardan shafts using the cardan shaft bracket
lite ALI 2.874 SET used in conjunction with “ROTALIGN smart EX edition”. Cardan
drives are installed and operate with a large offset between the driver and the driven
shaft. The spacer shaft is set at a considerable angle (usually 4° to 6°) in order to
ensure sufficient lubricant circulation, which in turn prevents the universal joints from
seizing. Excessive misalignment of such a configuration leads to rapid fluctuation of
the driven shaft RPM during operation, which holds grave consequences for electron-
ically-controlled
synchronous and asynchronous AC drive motors.
Precise alignment reduces the rotational irregularities of the cardan shaft to a minimum,
so that the uneven bearing loading during cardan shaft rotation is also minimized, the
service life of the components is extended and the chance of unexpected machine
failure is reduced.
The measurement procedure described here allows precise measurement of machines
joined by cardan shafts over distances of up to 3 m (10 ft) and shaft offsets of up to
400 mm (15 3/4 in) using “ROTALIGN smart EX edition”.
1. Mounting the faceplate to the rail

a. Slide the the faceplate down the rail as shown in figure (1a) below. The four
T-nuts should sit in the grooves.
b. After positioning the faceplate on the rail, tighten the four socket head screws
using the provided M6 allen key.
c. Mount the bracket assembly to the coupling face of the non-rotatable shaft. If
the coupling face has a raised rim, the precision machined spacers are used as
125
shown in order to separate the bracket faceplate from the coupling face.
(Without the spacers, there would be direct contact between the faceplate and the
coupling surface surrounding the bolt holes – exactly the location where the faceplate
and coupling are being joined.) The washers prevent the nuts from marking the
coupling surface when tightened.
1a 1b 1c
Depending on the relative positions of the machines joined by the cardan shaft, an in-
clinometer or spirit level should be used to position the bracket assembly at the same
angle as the cardan shaft when installed, before tightening down the bolts. A design
drawing from the machine manufacturer can be helpful in determining the intended
horizontal and/or vertical offset between the machine coupling halves. The inclination
can be calculated from these horizontal and vertical distances as follows: Inclination =
arctan (vertical offset / horizontal offset)
2. Mounting the laser holder assembly on to the rail

a. Loosen the handwheel slightly, then slide the laser holder assembly down the If a specific offset
center groove of the rail, with the T-nut acting as a guide. between the driver and
b. Fasten the laser holder assembly onto the rail at the appropriate position by driven machine shaft
tightening the handwheel. centerlines is desired, slide
the laser holder along the
3. Mounting and adjusting the ROTALIGN laser rail to a point where its
a. Slide the two black distance sleeves down the support posts. own centerline of rotation
b. Slide the laser onto the posts until it rests on the distance sleeves. is located precisely at this
c. Mark a set of target crosshairs on the shaft rotation centerline of the other desired amount of offset
machine coupling (if the flange has a center hole, a dust cap can be inserted to from the centerline of
provide a temporary target surface). rotation of the coupling
d. Switch on the laser and adjust the beam to strike the center of the target on the to which the faceplate is
opposite coupling: attached.
126
3b
2a
Prior to mounting the laser, adjust both yellow adjustment thumbwheels to the
approximate center of their travel range so that the laser beam is emitted as
straight as possible.

Note
› For rough adjustment, loosen the handwheel and slide the holder along the
rail; loosen the yellow locking knobs to adjust the beam height.
› For fine adjustment, use the thumbwheels on the laser housing to center the
laser beam onto the target.
e. Rotate the laser holder one complete revolution. The laser beam should not drift
from its target at any time; if the laser drifts away from the target, repeat the
previous step.

To adjust the beam, note start position of the beam, then rotate the laser holder
180°. Note position of the beam. Return to the start position and using the
yellow adjustment thumbwheels, adjust the beam in the horizontal and vertical
Note
directions to a position midway between the beam’s start position and 180°
position. Repeat this process until you can rotate the laser holder through one
complete revolution without the beam moving from its original position.
f. Switch off the laser and remove it from its holder.

g. Using the provided M5 allen key, loosen the support posts and slide them
through the bracket frame so that they protrude from the other side.
h. Remount the laser onto the support posts
i. Use the chain-type bracket to mount the sensor on the opposite machine shaft,
then connect it to the ROTALIGN Ultra computer.
j. Switch the laser back on, then adjust the beam onto the sensor (refer to ‘Laser
beam adjustment’ in chapter 5). 127
3i
3e
4. Set-up and measurement

a. Switch on the system computer.
b. Set up the machines (refer to section 7.2.3 ‘Coupling properties’ on page 57)
and select ‘Change to cardan’ in coupling properties.
c. Enter all required machine dimensions.
d. Remove the sensor dustcap and press m. The laser beam location should be
apparent in the adjustment screen.
e. Press q. A context menu appears. Use the context menu item ‘Measurement
mode’ to select the ‘Multipoint’ measurement mode. (For details about this
mode refer to chapter 7.).
128
f. Press e to confirm selection.

g. Place the specially designed beam adjustment cap (ALI 3.606 UN) that helps
with monitoring the position of the beam during rotation on the sensor lens and
center laser beam (for details on ‘laser beam adjustment’ refer to chapter 5).
h. Press e to take the first measurement.
i. Rotate the sensor to the next measurement position.
j. Rotate the laser holder with laser and observe the detector view in the
measurement screen (below): at the moment when the laser dot crosses the
Y-axis, press e to take the next measurement.
k. Repeat steps i and j to take measurements in at least three positions over at least
60° of rotation. (Taking more position measurements improves the reliability of
results.).
l. When enough measurement points over at least 60° rotation have been taken, Alternatively, stop
press e to stop measurement. measurement by pressing
q followed by 3.
129
Laser beam
Sensor
Adjust laser beam
4g 4j Laser crosses
sensor Y axis (measurement)
6. Evaluation and alignment

Since offset does not affect the performance of cardan shafts, only angularity must
be corrected here.
a. Press k to view alignment results.
In this example the

automatic tolerance evalua-
tion returns a happy face in
both horizontal and vertical
directions. This indicates
that the machines are
aligned within the specified
tolerances and therefore no
further aligning action may
be required.
If a specific amount
b. Cycle through the feet results using k/f/g.
of offset between the
machine shafts was
desired and the laser
holder assembly was set
up to this precise offset
as described in step 2b
above, then, after the
angular alignment of
the movable machine
130
is completed, remount
and readjust the laser
as described in steps 3a
through e and proceed
to adjust the movable
machine in a parallel
manner both vertically
and horizontally until
the beam spot hits the
movable machine shaft‘s
centerline of rotation,
taking care not to change
its angular alignment.
Flanged machines
c. If the machines are out of tolerance, reposition them with the help of the MOVE
function (refer to pages 76 – 79).
d. Remeasure to determine the new alignment condition.
Flanged machines
The diagram at the bottom of the page shows a typical vertical machine arrangement
with one machine mounted on top of the other using a bolted 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 smart EX edition” calculates the shimming thickness for each flange bolt.
Offset is corrected by positioning the flange laterally.
Set-up
Before commencing with this section, please acquaint yourself with chapter 5
‘Horizontal machine alignment’ starting on page 41.
Note
The laser and sensor are mounted on either side of the coupling as with 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.
131
Typical vertical machine
arrangement comprised
of one machine mounted
on top of the other with a
3:00 9:00
bolted flange.
1:30 10:30
0
Evenly-spaced marks are

made on the bearing
housing beginning with 0 as
the reference and numbered
clockwise looking down
onto the shaft.
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. This
ensures that lateral corrections can be performed with the minimum of effort.
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 laser to sensor, beginning with 0 first, followed by 1:30, 3:00, 4:30,
6:00, 7:30, 9:00 and 10:30.
For circular housings, measure the circumference of the coupling housing and divide by
4:30
3:00
1:30
eight. Use this distance to make eight evenly-spaced marks on the housing beginning
0
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. (Refer to
the diagram on the previous page.) The shaft is numbered
counterclockwise looking
2. Mounting components and selecting machine orientation down the shaft, starting
a. Mount the sensor and laser on either side of the coupling, ensuring that they are at 0 followed by the clock
aligned exactly with the 0 or reference mark. positions 1:30, 3:00, 4:30,
b. Connect the sensor to the system computer then switch on the device. 6:00, 7:30, 9:00 and 10:30.
c. From the dimension screen that appears, press q. With the context menu
displayed, use the navigation keys to highlight ‘Train orientation’ > ‘Vertical
train’.
Alternatively, with the

132 context menu displayed,
select vertical train orienta-
7
tion directly by pressing
then 2. A hint requiring
confirmation to the selected
train orientation appears.
d. Confirm selected train orientation by pressing e. A hint appears requiring the

acknowledgement of the change. Press e to acknowledge.
Flanged machines
3. Editing flange configuration

A typical vertical machine train arrangement consists of machines mounted together
using a bolted flange. To configure the flange proceed as follows:
a. Proceeding from 2 above, and with MTBM highlighted press e then use g
to highlight “Change to flange”.
with the menu items
displayed.
b. Confirm selection by pressing e. The “Edit flange” screen appears.
The parameters that can be

edited are number of bolts,
outer flange and bolt circle
diameters. These parameters
are highlighted using the
navigation keys, and edited
directly using the data entry
133
keys.
c. To edit the flange pattern, press q while in the ‘Flange edit’ screen.
The following flange patterns are available:
› Circular flange
› Square flange
› Square flange - circular bolt pattern
d. Press 3 to access the flange configuration submenu items.
1 = circular flange
2 = square flange
3 = square flange -
circular bolt pattern
e. It is possible to select predefined bolt patterns. This option defines the number
of bolts and their respective positions.
› i) Press q while in the “Edit flange” screen.
134
› ii) When the context menu appears, press 4.
The option of selecting

predefined bolt positions
is currently possible with
circular bolt patterns only.
Flanged machines
› iii) Confirm bolt pattern selection by pressing e.
4. Enter dimensions
Press ß or d to return to the dimensions screen.
a. Enter the coupling center-to-sensor distance.
b. Enter the coupling diameter. The default is 100 mm.
135
c. Enter the coupling center-to-flange distance.
d. Enter the RPM. The default is 1500. (1800 if units option is set to US units.)
136
The flange configuration can also be edited from the above screen by highlight-
ing the flanged machine then pressing e.

Note
To edit the flange

configuration, use g
to highlight ‘Edit flange’
then confirm selection by
pressing e. Alternatively
press 5 with the context
menu displayed. The “Edit
flange” screen described in
3 previously appears.
Flanged machines
Measurements can now be made.
5. Measure
a. Press m and then center the laser beam.
For vertically oriented machine trains, static measurement mode is selected

automatically.

Note
b. Rotate the shafts to the first measurement position. The reference mark and the
measurement position 0 must be aligned with each other. Use the navigation
keys to place the screen hour hand to correspond with the position of the laser
and sensor on the shafts.
c. Press e to take the first measurement point.

d. Rotate the shafts to the second measurement position (e.g. 1:30). Move the 137
screen hour hand using the navigation keys to correspond with the new position
of the laser and sensor on the shafts. Press e to take measurement point.
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.

Note
6. Results
When measurement is complete, press w to view results.
The ‘all-in-one’ results

screen shows the coupling
gap and offset values in the
0-6 and 3-9 directions for
short flex coupling and the
flange correction values.
138
Sign convention (for vertical machines)
POSITIVE GAP opens towards 0:00 or 3:00
POSITIVE OFFSET if the top coupling half is offset towards 0:00 or 3:00

Note
Cycle through the coupling results and the flange correction positions using either
w, f or g.
Flanged machines
In this example, the sad face

smiley indicates that the
flange needs to be adjusted
in the 0-6 direction.
Shimming corrections are accessed by pressing q while in the “Feet results” screen.
Use g to highlight the context menu item ‘Flange/Bolt results’.
139
Shimming corrections screen
may be accessed directly
If the context menu is
accessed from “Coupling
results”, shim corrections
for each flange bolt are
displayed by pressing 6.
Confirm selection by pressing e. The shim corrections screen appears.

The shimming correction

value (6.14 mm) and the
corresponding bolt are
highlighted automatically
as shown.
The shim corrections are numbered to correspond with the bolt positions. The bolt
position corresponding to the currently highlighted calculated shim correction value
appears numbered and highlighted with a yellow dot.
Use f/g to cycle through the shim values.
Use h/i to set the type of shimming required. The following options are available: The flange correction
Bolt correction (+) – means all shimming corrections are positive (add shims) format is accessed via
Bolt correction (-) – means all shimming corrections are negative (remove shims) the “Flange corrections”
Bolt correction (+) – means all shimming corrections are minimized (optimized). screen context menu
Therefore half of the corrections will be negative and half of them positive. This item ‘Change correction
option results in zero axial movement of the shaft. format’.
7. Machine alignment
Alignment is carried out by correcting angularity and offset.
140 Correcting angularity

a. Loosen the flange bolts and lift the upper machine.
The machine bolts must be undamaged and removable.
b. Angularity corrections are made by shimming. The shim correction screen shows

CAUTION
the shimming values at the respective bolt locations. Insert (or remove) shims
with the correct thickness under the selected bolt.
Use good quality shims such as PERMABLOC or LAMIBLOC.
c. Retighten the bolts and then remeasure to verify shimming results and determine
Note
the exact alignment condition.

Flanged machines
Correcting offset
The correction of offset misalignment is carried out using the live MOVE function.
a. Access live MOVE by pressing q while in “Results” screen. Use g to
highlight the context menu item ‘Move’.
Alternatively, access Move

b. Confirm selection by pressing e.
If move is selected from the coupling results screen a hint requesting the direction
to carry out the move appears.

Note
c. On confirmation the screen used to position the sensor and laser for the required
move appears. Select the most convenient position.
141
d. Rotate shaft to any of the eight positions highlighted in green. These are 1:30,
3:00, 4:30, 6:00, 7:30, 9:00 and 10:30.
e. Use i to position the sensor on the screen to correspond to the position of the
sensor and laser on the shafts.
f. Press e to start live MOVE.
If the laser beam is centered, Live MOVE starts automatically. If beam is not
centered, a hint to center the laser beam appears on the display.

Note
h. Loosen the flange bolts. Move the machine laterally in the direction of the bold
yellow arrow as indicated in the live MOVE display.
i. Corrections should be brought as close as possible to zero. The smiley changes

from a sad face to OK to a happy face. At the same time the system computer
LEDs change from red to amber to green and to blue.
142
Use appropriate tools (e.g. levers) to position the machine.
Take care not to let the shims slip out of place during lateral positioning.
When machine is correctly positioned, tighten the bolts back down. Remeasure
to check if the new alignment condition is within tolerance.
The orientation of the Move may be changed via the context menu of the “Live
Move” screen.
143
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144
Appendix
Appendix
Suggested shaft alignment tolerances
[RPM] metric [mm] inch [mils]
Soft foot any 0.06 mm 2.0 mils
Short “flexible” couplings Acceptable Excellent Acceptable Excellent

Offset
600 9.0 5.0
750 0.19 0.09
900 6.0 3.0
1200 4.0 2.5
1500 0.09 0.06
1800 3.0 2.0
3000 0.06 0.03
3600 1.5 1.0
6000 0.03 0.02
7200 1.0 0.5
Angularity 600 15.0 10.0 145
(coupling gap difference

750 0.13 0.09
per 100 mm or 10”
900 10.0 7.0
diameter
1200 8.0 5.0
1500 0.07 0.05
1800 5.0 3.0
3000 0.04 0.03
3600 3.0 2.0
6000 0.03 0.02
7200 2.0 1.0
[continued]
[RPM] metric [mm] inch [mils]
Acceptable Excellent Acceptable Excellent
Spacer shafts and 600 3.0 1.8

membrane (disk)
750 0.25 0.15
couplings
900 2.0 1.2
Offset
(per 100 mm spacer 1200 1.5 0.9
length or per inch of
1500 0.12 0.07
spacer length)
1800 1.0 0.6
3000 0.07 0.04
3600 0.5 0.3
6000 0.03 0.02
7200 0.3 0.2
146
Appendix
“ROTALIGN smart EX edition” technical data
Computer
CPU Intel XScale PXA270 running at 312 MHz
Memory 64 MB RAM, 32 MB Flash
Display Type: TFT, transflective (sunlight-readable), 65 535 colours, backlit LED
Resolution: 320 x 240 Pixel
Dimensions: 3.5 inch diagonal
Keyboard elements: Navigation cursor cross with up, clear and menu
keys; Alphanumeric keyboard with dimensions, measure and results hard
keys
LED indicators 4 LEDs for laser status and alignment condition
2 LEDs for wireless communication and battery status
Power supply Operating time: 18 hours typical use (based upon an operating cycle of
25% measurement, 25% computation and 50% ‘sleep’ mode)
Disposable batteries: 6 x 1.5 V IEC LR6 (“AA“)
Only use 1.5 V “AA” MN 1500 from Duracell or AccuCell AC 1800
rechargeable batteries
External interface USB host
USB slave
RS232 (serial) for transducer
Integrated wireless communication, class 1, transmitting power 100 mW
AC adapter/charger socket
Environmental protection IP 65 (dustproof and water spray resistant), shockproof
Relative humidity 10% to 90%
Intrinsic safety II 2 G Ex ib [ib] IIC T4, Zone 1
Certificate numbers: TÜV 08 ATEX 554162, IECEx TUN 08.0006
Temperature range Operation: -10°C to 50°C [14°F to 122°F]
Storage: -20°C to 60°C [-4°F to 140°F]
Dimensions Approx. 214 x 116 x 64 mm [8 7/16” x 2 1/2”]
Weight 865 g [1.9 lb]
CE conformity EC guidelines for electric devices (2004/108 EWG) are fulfilled
Sensor
147
Particulars 5-axis receiver: 2 planes (4 displacement axes), 1 inclination 360°
Environmental protection: IP 67 (submersible, dustproof)
Ambient light protection: yes
Operating temperature: 0°C to 45°C [32°F to 113°F
Storage temperature: -20°C to 80°C [-4°F to 176°F]
Dimensions: approx. 105 x 67 x 47 mm [4 5/32” x 2 5/8” x 1 55/64”]
Weight: approx. 190 g [6 7/10 oz.]
Measurement area: unlimited, dynamically extendible (U.S. Patent 6,040,903)
Resolution: 1 μm (0.04 mil) and angular 10 μRad
Accuracy (avg): > 98%
Measurement rate: approx. 20 Hz
Intrinsic safety II 2 G Ex ib IIC T4, Zone 1
Certificate numbers: TÜV 02 ATEX 1974
Laser
Particulars Type: GaAlAs semiconductor laser
Beam divergence: 0.3 mrad
Environmental protection: IP 67 (submersible, dustproof)
Beam power: < 1 mW
Wavelength (typical) 675 nm (red, visible)
Safety class: Class 2, FDA 21 CFR 1000 and 1040
Safety precautions: Do not look into laser beam
Power supply 9V alkaline manganese block battery (Duracell Procell
MN 1604)
Operating temperature: 0°C to 45°C [32°F to 113°F]
Storage temperature: -20°C to 80°C [-4°F to 176°F]
Dimensions: approx. 105 x 67 x 47 mm [4 5/32” x 2 5/8” x 1 55/64”]
Intrinsic safety II 2 G Ex ib op isb IIC T4, Zone 1
Certificate numbers: TÜV 02 ATEX 1864
Carrying case
Particulars Dimensions: approx. 105 x 67 x 47 mm [4 5/32” x 2 5/8” x 1 55/64”]
148
Appendix
Attachments
149
150
Appendix
151
152
Appendix
153
154
Appendix
155
Any new supplement to the issued certificates will be posted on the official
PRÜFTECHNIK website – www.pruftechnik.com.
Please visit the website on a regular basis for information on new and current

Note
products.
156
Appendix
157
158
Appendix
159
160
Index
Index
A
Adapter box ALI 12.500
ALI 12.500 12, 20, 74, 83 Adapter box
Adjustment tube intrinsically safe
ALI 3.608 64
OPTALIGN smart computer 6
ALI 2.811
ALI 12.504-2
rechargeable battery
USB A/B cable 7, 20
AccuCell AC 1800 12
USB A/B cable to printer 83
ALI 2.892 SET
ALI 12.511-2
Compact chain-type bracket
sensor cable 22
without pouch 7
Sensor cable
ALI 2.905
instrinsically safe
lens cleaning cloth 8
ALI 3.588 EX OPTALIGN smart computer 7
tape measure ALI 12.651-I 36
AC power supply/charger 12, 20
intrinsically safe 8
ALI 3.600-2 EX adapter box 7
intrinsically safe ALI 12.701
firmware certificate
ROTALIGN sensor 12
OPTALIGN smart shaft 8
ROTALIGN sensor
ALI 12.801 EX
case 12
ALI 3.608
case ROTALIGN smart
beam adjustment tube 9
ALI 3.610 EX intrinsically safe 5
laser ALI 13.700 CDS
ALIGNMENT CENTER/Resources CD set 9
ALI 13.701 CD
Laser 6 161
ALIGNMENT REPORTER CD 9
ALI 4.452 36
Alignment condition
USB memory stick 7
complete 67
ALI 12.200 EX
ALIGNMENT REPORTER
computer OPTALIGN smart
freeware 83
intrinsically safe 5 ALIGNMENT REPORTER CD
intrinsically safe computer ALI 13.701 CD 83
OPTALIGN smart EX 12 Alignment results
evaluation 68
Intrinsically safe computer 83
Alignment tolerances 73
ALI 12.201
Allen key
computer stand 5
battery compartment cover
computer 9
laser 9
case flap 9
All-in-one results 90 Coupling backlash 41

Anchor peg 42, 43 Coupling housing
ATEX 13 markings 132
Attachments 149 Coupling properties 57
Averaging 67, 111, 112 Coupling settings 57
Averaging screen 112
D
B
Data entry keys 17
Batteries Data management 38
AA size 19 Data storage 14, 15
Default sensor 33
disposal 19
Default settings 33
replacing 18 Device settings 26
Battery Dial indicator readings 62
disposal 21 Distance marking
Bolted flange 131 laser 47
Bolt pattern DOC 12.100.en
predefined 134
pocket guide
Bracket
ROTALIGN smart EX 8
compact chain-type 43
DOC 12.200.en
mounting procedure 42
operating instructions
Bracket sag 63
ROTALIGN smart EX 8
C
E
Cable clip 44
Calibration 22 Editing box 51, 54
Cardan 58, 59, 115 Electromagnetic compatibility 11
beam adjustment cap Electronic inclinometer 131
Extend
ALI 3.606 UN 129
measurement range 81
faceplate Extend option 108
mounting 125 Extra-thin bracket
162 ALI 2.109 SET 24
mounting
laser 126
F
Cardan drives 125
Caution Flange
safety symbol 11
correction format 140
CE compliance 11
Flange configuration 136
Check mark 54, 71
Compact chain type bracket editing 133
Flanged machines 115
allen key Flanged-machines
0 0739 1057 9 shim corrections 140
Compact magnetic bracket Flange-mounted machines 131
ALI 2.112 24 Flange pattern 133
Component labelling 15 Function keys 17
Configuring printer 85
Coupling H
outer diameter
Horizontal train 49
O.D. 44
specifications 68
Index
I Measurement mode
Multipoint 104
IECEx 13
Pass mode 106
Image upload 28
Inclinometer Static 104
electronic 22 Measurement modes 66, 103
Infinirange 108 Measurement range
Interface connection 14 extending 65, 108
IP65 11, 14 Measurement report
IP67 11, 14 pipe strain 101
IP classification 11 Measurement table
average calculation 71
L Mounting
laser 44
Laser
sensor 44
9 V block battery 21
Multiple feet
ALI 3.610 EX 21
results 69
class II 21 Multiple feet calculator 69
wavelength 21
Laser battery 21 N
replacing 23
Navigation keys 17
Laser beam
Navigation shortcuts 25
adjustment 104 Negative dimensions 48
class II 13 Note
Laser block battery safety symbol 11
9V alkaline manganese
Duracell Procell MN 1604 12
O
Laser dust cap OK symbol
ALI 3.607 6
within tolerance 72
Laser safety 13
Lateral positioning 76, 77
Licence manager 34 P
Live Move 76, 78, 122, 124
163
PDF
Live MOVE
measurement report 36
vertical machines 142
PDF file 74, 86
Locking knob 44
Pipe strain 98
Power supply
M
1.5V AA batteries
Machine name 50
MN 1500 12
Machine train
MN 1500 from Duracell 18
alignment 115
reachargeable batteries
Move corrections 122
Magnetic bracket set AccuCell AC 1800 12
ALI 2.761 SET 24 Printer configuration 36
Magnetic sliding bracket Printing options 85
Printing reports 83
ALI 2.230 24, 107
Measurement arc 104
Measurement details 72
Q T
Quick alignment 89 Technical data 147
Temperature range 13
R Thermal growth 52
disenable values 54
Rechargeable battery Thermal growth calculator 55, 56
AccuCell AC 1800 18 Tolerance
Regional settings 29 acceptable 72
Repeatability 81 excellent 72
Report options 40
outside 72
Results resolution 33
Tolerances 60
Resume 111
Resume policy 29 user defined 60
Tolerances table 145
Tolerance table 61, 73, 74
S Train elements 116
Safety symbols 11
Sensor U
ALI 3.600-2 EX 22
USB A/B cable
disconnecting 45
ALI 12.504-2 20
Sensor cable
ALI 12.511-2 45
V
Sensor dust cap
ALI 3.606 6 Vertical machine 131
Serial number range 12 Vertical machines
Setting correcting offset 141
Boot up screen 28
Shaft markings 132 W
Shaft settings 37
Shimming 76, 78 Warning
Shims
safety symbol 11
good quality 75, 140 WEEE directive 15
164
Sign convention 68, 77 Workflow assistant 33
vertical machines 138
Six-foot machine 69 X
Smiley 72
happy symbol 75 XY view 94
Soft foot relative coordinates 114
angular 91 XY View 113
induced 92
parallel 91
Soft foot correction
Angular 97
parallel 97
Spacer coupling 48
Splash screen 46
Supplement
new 155
ROTALIGN® smart EX
Operating handbook - Shaft alignment
PRÜFTECHNIK
Alignment Systems GmbH
Freisinger Str. 34
85737 Ismaning
Germany
Tel +49 89 99616-0
PROVEN QUALITY
Fax +49 89 99616-100
Made in Germany info@pruftechnik.com
Global Presence www.pruftechnik.com
Qualified Support
Quality Service
A member of the PRÜFTECHNIK Group

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ROTALIGN® smart EX

Operating handbook - Shaft alignment

PRÜFTECHNIK Alignment Systems GmbH

ROTALIGN® is a registered trademark of PRÜFTECHNIK Dieter Busch AG. PRÜFTECHNIK

The system is delivered together with ALIGNMENT REPORTER, a PRÜFTECHNIK

PRÜFTECHNIK Alignment Systems

Chapter 1: ROTALIGN smart EX package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Chapter 2: Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Chapter 3: ROTALIGN smart EX – an overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Chapter 4: Conﬁguration and data management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Chapter 5: Horizontal machine alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Chapter 6: Quick check measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Chapter 7: Dynamic alignment features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Chapter 8: Special alignment applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Chapter 1: ROTALIGN smart EX package

ROTALIGN smart intrinsically safe package ALI 12.001 EX

ALI 12.801 EX Intrinsically safe ROTALIGN smart case

ALI 12.200 EX OPTALIGN smart intrinsically safe version

ALI 12.201 Computer stand

ALI 12.801 EX ALI 12.200 EX ALI 12.201

ALI 3.600-2 EX Intrinsically safe ROTALIGN sensor

ALI 3.610 EX Intrinsically safe laser including dust cap

ALI 12.500 Adapter box for intrinsically safe

ALI 12.500 The adapter box

USB port for printer

AC power supply port

ALI 3.600-2 EX ALI 3.610 EX

ALI 12.511-2 Sensor cable connected to instrinsically

ALI 12.651-I AC power supply/charger for adapter

ALI 12.504-2 USB A/B cable for connecting to printer or PC

ALI 4.452 USB memory stick

ALI 2.892 SET Compact chain-type bracket without

ALI 12.651-I ALI 4.452

ALI 12.504-2 ALI 2.892 SET

ALI 12.701 OPTALIGN smart shaft

ALI 2.905 Lens cleaning cloth

ALI 3.588 EX Intrinsically safe tape measure mm/inch

DOC 12.100.en ROTALIGN smart EX pocket guide

DOC 12.200.en ROTALIGN smart EX operating

ALI 2.905 ALI 3.588 EX

ALI 13.700 CDS ALIGNMENT CENTER CD/Resources CD

ALI 13.701 CD ALIGNMENT REPORTER CD

ALI 3.608 Beam adjustment tube

0 0739 1055 Allen key – 2.5 mm [used to undo the

0 0739 1057 Allen key – 4 mm [used to lock/unlock

ALI 13.700 CDS

This page intentionally left blank

Chapter 2: Safety notes

This symbol denotes general information and tips regarding operation of

This symbol denotes information which must be followed in order to avoid

This symbol denotes information which must be followed in order to avoid

Numbers in red circles indicate the corresponding operating step described in 1

CE compliance and EMC

ROTALIGN smart EX has been tested to the scope of:

Notes for intrinsically safe models

 When equipment to be aligned is located in an explosive environment, the

 The circuit parameters meet the intrinsic safety requirements Ex ib IIC.

 The maximum cable length between the computer [“ROTALIGN smart EX

 The intrinsically safe computer [“ROTALIGN smart EX edition”] may be

 The installation and operation of the intrinsically safe ROTALIGN smart EX

 The EC type examination certiﬁcates (ATEX) and the IECEx certiﬁcates of

Temperature effects and ﬂuctuations

Dust and water seals

When equipment to be aligned is located in an explosive environment, the

The circuit parameters meet the intrinsic safety requirements Ex ib IIC.

The maximum cable length between the computer [“ROTALIGN smart EX

The intrinsically safe computer [“ROTALIGN smart EX edition”] may be

The installation and operation of the intrinsically safe ROTALIGN smart EX

The EC type examination certiﬁcates (ATEX) and the IECEx certiﬁcates of

d The ‘Dimensions’ key is used to initiate entry of machine dimensions.

c The ‘Clr’ (Clear) key is used to delete information entered inadvertently.

h i f g The navigation keys are used to navigate through the

e The ‘On/Off/Enter’ key is used to perform the dual function of switching

‘Results resolution’ is used to set the results resolution at either ‘Normal’ or

Cardan units – used to set the desired measurement unit