Alignment Training

There is a better way!
Copyright 1997 PRFTECHNIK AG
Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
Causes of machine damage
MI
EN
HERS
T
O
Machine vibration
AL
Coupling damage
Seal wear
M
IG N
Bearing damage
A1
What is meant by 'alignment?'
Rotating axes must be colinear during operation
A2
Laser-optical shaft alignment cuts vibration alarms

Vibration alarms/year
700
600
500
Misalignment
400
300
Other
(bearing damage,
unbalance,
looseness)
200
100
0
1987
1991
1995
Source: Shell Petroleum, Stanlow, UK
A3
Laser-optical shaft alignment reduces repair incidence
110
Pump
repairs
100
90
80
70
60
55
50
Mechanical
seal
45
repairs
40
35
30
25
20
15
1988
1989
1990
1991
1992
1993
1994
1995
Source: Hoechst AG, Gendorf/Germany

A4
Misalignment increases coupling load

Normal view of
coupling as installed
Infrared photos of thermal radiation
Without OPTALIGN
Infrared thermograms courtesy of Infraspection Institute
With OPTALIGN
A5
Consequences of misalignment: machine damage

vibration analysis
Excessive vibration
shock pulse reading
Bearing damage
Seal wear from shaft bending

Seal ring opens,
dirt, liquid and gas or
process fluid enter the bearing,
gas escapes under pressure
A6
Four alignment parameters
Vertical offset
Vertical angularity
Horizontal offset
Horizontal angularity
A7
Alignment methods in comparison

Straightedge
Dial indicator
OPTALIGN PLUS
Method
Operator
The Wizard
The Specialist
Anyone
NOV
Training
required
Alignment
resolution
Years of
experience
max. 4 mils
1/10 mm
23
Weeks
to months
0.4 mil
1/100 mm
A few
hours
ON
OFF AUX
0.04 mil
1/1000 mm
A8
How accurate are dial indicator readings?
455
45
40 10
10
40
35 15
35
20
30
Indicator bracket sag
15
30
25
25
20
Play in
mechanical linkages
455
45
10
40 10
40
15
35
15
35
20
30
30
25
25
20
Internal friction /
hysteresis
Tilted dial indicator

Resolution
1/100 mm (0.5 mil)
(rounding loss)
Reading errors:
sign error
parallax error
mirror image readings
Axial shaft play
A9
The OPTALIGN PLUS System
B1
Principal advantages of OPTALIGN PLUS

OPTALIGN PLUS gives you the benefits of:
10 years' industry-proven
laser alignment technology
Robust laser technology

withstands the shop floor
Little shaft rotation required

to determine alignment
Simple 3-key operation:
DIM
1. Enter dimensions
2. Rotate shafts
3. Read results!
Reliable universal brackets for

quick, easy mounting
(magnetic version also available)
Only one cable:

eliminates tangling
Space-saving reflector design

fits into places too tight
for other laser systems or dial gages
low weight reduces sag
Patented Unibeam principle means

only one laser beam to adjust
Handles gross misalignment or
great separations (e.g. spacer shaft)
thanks to Infinirange
measurement range extension
Calibration to local or
international standards
Instructions store in rear

panel for quick reference
IP65 protection:
resists shock, water drops & dust
B2
New features of OPTALIGN PLUS

OPTALIGN PLUS gives you
Flexible shaft rotation:
a) Restricted angle
b) Continuous or by segments
Non-volatile
data storage
Full PC support
available
c) User-defined positions
Interchangeable
transducers
Freedom from
backlash effects
Intelligent power management
for longer battery life
Tolchek alignment tolerance
indication at a glance
Automated reporting via
direct printer connection
B3
The OPTALIGN PLUS measurement principle
B4
The OPTALIGN PLUS transducer
Beam adjustment LEDs

Laser inactive
IP 67 housing
Adjustment OK
End of range
Out of range
Locking
knobs
Out of range
Scratch-resistant lens
Power/data
cable
End
-1 -1
Linearized area
Detector surface
B5
OPTALIGN PLUS laser emission
Randomized pulse interval

prevents vibration interference
Ene
Laser safety Class 2

rgy
Tim
EEx ib IIC T4
Zone 1
(Optional)
B6
Position detector linearization

Highly accurate linearization = highly accurate alignment on first attempt!
'Raw' detector response
Linearized response
1.1 4.2
0.8 5.3
0.6 6.0
1.5 6.2
1
3
Calibration data
stored in transducer
1.0 4.0
1.0 5.0
1.0 6.0
2.0 6.0
3.0 6.0
(2.4, 6.3) ------------------------> (3.0, 6.0)
B7
Offset and angularity from the calculation ellipse

Offset
Y1
0
Vertical
Y1(0:00) - Y1(6:00)
Angularity
(Y2 - Y1)
9
Horizontal
Y1(3:00) - Y1(9:00)
Vertical
(Y2 - Y1)(3:00) - (Y2 - Y1)(9:00)
Horizontal
(Y2 - Y1)(0:00) - (Y2 - Y1)(6:00)
B8
The OPTALIGN PLUS control unit

ON
OFF AUX
PC/Printer
LCD display
Transducer
ON
OF
F A
U
Transducer should remain

connected at all times
during operation!
Sliding key cover
B9
B10
2
AM
C
R 14 5 V
y L 14 1,
Bab No 40
.
ble .
ble
gea
n!
rfe .
har gea
we
t rec har
uer ladbar! No rec
Fe
ins deraufin fire ! non
ht
e
feu
Nic ht wie lod r au
Nic y exp jete
Ma pas
Ne
AM
C
R 14 5 V
y L 14 1,
Bab No 40
MAIN battery set

6x 1.5V
LR6
.
ble .
ble
gea
n!
rfe .
har gea
we
t rec har
uer ladbar! No rec
Fe
ins deraufin fire ! non
ht
e
feu
Nic ht wie lod r au
Nic y exp jete
Ma pas
Ne
N1
60
LE
L
IN
AL
LK
V
CAE
,0
RA R61 9
U
L
6
D
E
IN
AUX battery
9V
6LR61
ON
MAIN
battery set
ON
OFF AUX
AUX
battery
OFF AUX
2 power supplies for extended operation
The OPTALIGN PLUS LCD display
Measurement status and user guidance
Clear display of results

Coupling
alignment
condition
Current
measurement
coordinates
Vertical gap
lies within
tolerance
Display
prompts user
to rotate shafts
Gap opens
toward
bottom of
coupling
Elapsed
rotation
sector
Alternating
display
B11
Preparation for alignment: machine mobility
Machine puller
C1
Shaft and coupling play

Axial shaft play:
No effect
Coupling torsion play (up to 5):

No effect
C2
Why is OPTALIGN PLUS unaffected by torsion play?

Measurements are considered
only during synchronous rotation of shafts:
Measurement evaluation:
shafts turn together (without play)
Last 5 of
shaft rotation
First 5 of
shaft rotation
C3
Soft foot
Parallel
soft foot
Angular
soft foot
C4
Soft foot correction with OPTALIGN PLUS
Quick and easy soft foot measurement

before every alignment job
Begin with foot bolt tightened
Loosen bolt to measure
Correct with shims
C5
Vertical correction with PERMABLOC shims
PERMABLOC
AP 60 x 50 x 0,1
Size
X
A
60
B
80
C
100
D
130
Y
50
70
80
105
Z
15
22
32
44
M12
M18
M27
M36
C6
Mounting OPTALIGN PLUS

A
C7
Laser beam adjustment

1. Vertical
Adjustment
cap
x, y coordinates
of reflected beam
Adjust to (0,0)
Alternating
display
2. Horizontal
C8
Standard alignment procedure

Take alignment readings with only three keys
ON
OFF AUX
See alignment condition in a matter of minutes
1. Machine dimensions
2. Measurement
3. Results
C9
Machine dimensions
Beam deflector
ALI 5.106
C10
Continuous sweep measurement mode

For coupled shafts
As little as 60 shaft rotation required!
Measurements
are registered
continuously,
automatically
Current
measurement
coordinates
Display
prompts user
to rotate shafts
Elapsed rotation
(internal
inclinometer)
Alternating
display
C11
The 0, 3, 6, 9 measurement mode

For coupled shafts
(uncoupled shafts: see next viewfoil)
Inclinometer
ALI 5.020
8 fixed measurement positions

(at least 3 positions required)
6
C12
Uncoupled or non-rotatable shafts

When one or both shafts cannot be rotated
8 possible measurement positions
Stationary
shaft
Inclinometer
ALI 5.020
(2 required)
Rotatable
shaft
Oil
Magnetic
sliding bracket
ALI 2.230
C13
The multipoint measurement mode

For coupled shafts
At least 5 measurement positions
As little as 60 shaft rotation required!
C14
Are alignment corrections needed?
Results screen gives the answer at a glance:
Coupling alignment condition

Alignment
meets tolerance:
no realignment
necessary
Coupling gap
opens downward
C15
Vertical alignment corrections
Clearly indicates required shimming corrections

Correction at
machine feet
Foot to be
raised
(insert shims)
Front foot
correction
1.31 mm
C16
Horizontal adjustment monitoring: the MOVE function

Guides the user on screen through machine positioning
0.23 mm
(away from user)
C17
Accessing special functions
Alignment targets
Enter thermal growth
offsets and angularity
Function key
Calls up special functions
such as coupling type selection, 6-footed machine setup,
date/time setting
Vertical flanged
machines
Printer
Alignment program
Directs output
to printer
Save / open file

Stores/recalls up to
99 machine setups
and results
Sliding cover
Slides down to expose
6 special function keys
D1
Thermal growth
D2
Entering alignment target values
Expected growth
of motor
0.2 mm
0.2 mm
'Cold' position (coupling targets)
- or -
Expected growth (at machine feet)
D3
Alignment of vertical machines
Angularity:
corrected by flange bolt shimming
Offset:
corrected by lateral positioning
D4
Vertical machines: measurement procedure
Dimensions
3
6
Taking measurements
1. Rotate shafts to match shaft and housing markings

2. Enter position in terms of 0, 3, 6, 9
D5
Vertical machines: alignment corrections

Lateral correction
monitoring ('MOVE')
Shimming corrections
D6
Storing and loading measurement files

OPTALIGN PLUS stores up to 99 measurement sets
Store results for later comparison,
evaluation or transfer to a PC
ON
99
OFF AUX
2 3
Most recent
measurement
set = 0
(inaccessible by PC)
Set up alignment jobs

in advance on a PC with
OPTALIGN PLUS Commander
Load with
at startup
D7
OPTALIGN PLUS special functions overview

+
+
Print ASCII list of special function numbers
Print ASCII list of available languages
Display position detector coordinates
Select units (mm/inch)
Call up intermediate foot corrections
Display time and date
Set time and date

Select report language
Set number of readings for
measurement point averaging
Delete all stored measurements
Display test (all segments)
Display test (segments in sequence)
Extend measurement range

Keyboard test
Select stationary machine feet
Select coupling type
Hardware/software version numbers;

transducer ID number
Select default result display
Memory test
Select default coupling diameter
Reset to original default values
Select default RPM
Create a new machine
D8
Coordinate display / setting mm/in. units

Display detector coordinates
in 1/1000 mm or 1/10000 in.
Select display units:

mm or inches
1 inch = 25.4 mm
1 mm = 0.03937 inch
Beam adjustment
coordinates,
scaled (-9 to +9)
Horizontal
coordinate
in mm
Horizontal
coordinate
in inches
D9
Machines with more than four feet
OPTALIGN PLUS calculates corrections for any desired foot position
200
m
7
0.4
1. Enter desired intermediate location
mm
2. OPTALIGN PLUS displays required correction
D10
Alignment tolerance tables

OPTALIGN PLUS
Soft foot
uses 'happy face' symbols to show

compliance with tolerances based
upon coupling type and RPM.
Angularity
(gap difference at coupling edge
per 100 millimeters diameter
'Excellent' tolerances fulfilled

Spacer shafts and
membrane (disk) couplings
Offset
(per 100 millimeters spacer length
or per inch of spacer length)
(No happy
face)
'Bad' = Out of tolerance:

Realign!
metric [mm]
inch [mils]
any
0.06 mm
2.0 mils
Short "flexible" couplings
Offset
'Acceptable' tolerances fulfilled
[RPM]
600
750
1500
1800
3000
3600
6000
7200
600
750
1500
1800
3000
3600
6000
7200
600
750
1500
1800
3000
3600
6000
7200
Acceptable
Excellent
0.19
0.09
0.09
0.06
0.06
0.03
0.03
0.02
0.13
0.07
0.09
0.05
0.04
0.03
0.03
0.02
0.25
0.12
0.15
0.07
0.07
0.04
0.03
0.02
Acceptable
Excellent
9.0
5.0
3.0
2.0
1.5
1.0
1.0
0.5
15.0
10.0
5.0
3.0
3.0
2.0
2.0
1.0
3.0
1.8
1.0
0.6
0.5
0.3
0.3
0.2
D11
OPTALIGN PLUS handles any amount of misalignment
Severe misalignment:
Laser leaves detector range during measurement
OPTALIGN PLUS extends detector range
Range extension procedure:

1. Turn back until coordinates reappear*
2. Press
3. Readjust beam, then press
4. Proceed with measurement
Position detector
*In 'Sweep' mode, 'Set0' appears:

proceed from Step 3.
D12
Selecting static machine feet
Allows selection of most convenient adjustment points
Static machine feet

(blink in display)
D13
Selection of coupling type

OPTALIGN PLUS allows
selection of result format
Single-plane = 'short'
(e.g. short flex or rigid couplings)
Results display and tolerance evaluation:

gap/offset
Two-plane = 'long'
(e.g. spacer shafts)
Results display and tolerance evaluation:

offset B / offset A
D14
PC support: The OPTALIGN PLUS Commander ALI 5.250

Data file
transfer and management
ON
Job setup in advance

on the PC
OFF AUX
Review alignment results
D15
9,0V
ALKALINE
6LR61
DURACELL
ALKALINE
DURACELL
MN1604
No 4014 1,5 V
No 4014 1,5 V
Baby LR 14 C AM2
Nicht ins Feuer werfen!

Nicht wiederaufladbar.
May explode in fire! Not rechargeable.
Ne pas jeter au feu! non rechargeable.
No 4014 1,5 V
No 4014 1,5 V
Baby LR 14 C AM2

No 4014 1,5 V
Baby LR 14 C AM2
au feu! non rechargeable.

AM2
Baby LR 14 NeCpas jeter


au feu! non rechargeable.

AM2
Baby LR 14 NeCpas jeter

No 4014 1,5 V
Baby LR 14 C AM2

IO
IN
The standard OPTALIGN PLUS package ALI 5.000
Op
era
tin
g
str

In
uc
tio
ns
E1
Compact chain-type bracket ALI 2.892set
Quick & easy mounting

on a wide range of diameters
E2
Compact magnetic bracket ALI 2.112set

Rigid mounting in a matter of seconds for uncoupled shafts as well
E3
Magnetic sliding bracket ALI 2.230

Perfect for measuring
uncoupled or non-rotatable shafts
Stationary
shaft
Rotatable
shaft
Oil on shaft end or

coupling flange
E4
Magnetic bracket for coupling bolt holes ALI 2.106set

No radial clearance required:
Laser beam passes through bolt hole
E5
Extra-thin bracket ALI 2.109set

For mounting in extremely narrow spaces
between coupling flange & machine housing
E6

Alignment Training

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Alignment Training

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There is a better way!

Copyright 1997 PRFTECHNIK AG

Causes of machine damage

Copyright 1997 PRFTECHNIK AG

What is meant by 'alignment?'

Rotating axes must be colinear during operation

Copyright 1997 PRFTECHNIK AG

Laser-optical shaft alignment cuts vibration alarms

Copyright 1997 PRFTECHNIK AG

Laser-optical shaft alignment reduces repair incidence

Source: Hoechst AG, Gendorf/Germany

Misalignment increases coupling load

Infrared photos of thermal radiation

Copyright 1997 PRFTECHNIK AG

Consequences of misalignment: machine damage

shock pulse reading

Seal wear from shaft bending

Copyright 1997 PRFTECHNIK AG

Four alignment parameters

Alignment methods in comparison

Copyright 1997 PRFTECHNIK AG

How accurate are dial indicator readings?

Indicator bracket sag

Tilted dial indicator

Axial shaft play

The OPTALIGN PLUS System

Copyright 1997 PRFTECHNIK AG

Principal advantages of OPTALIGN PLUS

Robust laser technology

Little shaft rotation required

Reliable universal brackets for

Only one cable:

Space-saving reflector design

Patented Unibeam principle means

Instructions store in rear

New features of OPTALIGN PLUS

The OPTALIGN PLUS measurement principle

Copyright 1997 PRFTECHNIK AG

The OPTALIGN PLUS transducer

Beam adjustment LEDs

Copyright 1997 PRFTECHNIK AG

OPTALIGN PLUS laser emission

Randomized pulse interval

Laser safety Class 2

Position detector linearization

(2.4, 6.3) ------------------------> (3.0, 6.0)

Copyright 1997 PRFTECHNIK AG

Offset and angularity from the calculation ellipse

Copyright 1997 PRFTECHNIK AG

The OPTALIGN PLUS control unit

Transducer should remain

Copyright 1997 PRFTECHNIK AG

Copyright 1997 PRFTECHNIK AG

MAIN battery set

2 power supplies for extended operation

The OPTALIGN PLUS LCD display

Measurement status and user guidance

Clear display of results

Copyright 1997 PRFTECHNIK AG

Preparation for alignment: machine mobility

Copyright 1997 PRFTECHNIK AG

Shaft and coupling play

Copyright 1997 PRFTECHNIK AG