rotalign ultra system manual

8/10/2019 ROTALIGN Ultra System Manual

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Dear Customer,

If you have any suggestions for improvement or corrections (notonly to this manual, but also to software or hardware), pleasedrop us a line. We would be glad to make improvements whereverpossible. We look forward to hearing from you.

PRFTECHNIK Alignment SystemsDocumentation DepartmentFax (+49) 89-99616-100Email: [email protected]

Edition February 2005Firmware version 1.20ALI 9.845.G

ROTALIGN

Ultra

System

Operating Instructions

Overview:

Part 1ROTALIGN UltraSystem operating instructions

Part 2ROTALIGN UltraShaft alignmentoperating instructions


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Contents

Chapter 1 Introducing ROTALIGN Ultra........ 1-4 to 1-14

ROTALIGN Ultra Shaft package ........................................................... 1-4

Safety notes ....................................................................................... 1-6

Getting to know ROTALIGN Ultra ....................................................... 1-7

Laser and receiver ............................................................................. 1-10

Chapter 2 Using ROTALIGN Ultra.................. 2-1 to 2-14

Available applications and options ...................................................... 2-1

ROTALIGN Ultra configuration ............................................................ 2-2Setting date and time .................................................................... 2-2Language selection........................................................................ 2-3Setting units .................................................................................. 2-3Power management ...................................................................... 2-4Printer set-up ................................................................................ 2-5Device info .................................................................................... 2-6Display settings ............................................................................. 2-7Word completion .......................................................................... 2-7Customization ............................................................................... 2-9Context menu items .................................................................... 2-12

Tips and tricks .................................................................................. 2-13

Index ................................................................................................ 2-14

Contents


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Foreword

ROTALIGN Ultra is a new generation portable laser alignmentsystem, used in the alignment of shafts, turbine components, bores,and the measurement of straightness and flatness of different typesof surfaces. This expandable system is both a welcome replacementfor the proven ROTALIGN PRO system and an addition to theexisting high-end range of alignment products from PRFTECHNIK.As with all PRFTECHNIK instruments, ROTALIGN Ultra is userfriendly. It has an intuitive user interface. It uses easy-to-follow iconsand comprehensive on-screen menus and hint texts, that even first-time users are able to operate it without difficulty.

ROTALIGNUltra is built to rugged industrial standards of shock andwater resistance. It contains a complete computer with a colour 480 x320 VGA display and oval-shaped function keys. The computeruses the well known PRFTECHNIK tradition of obtaining alignmentresults with only three function key presses.

The system also uses the existing ROTALIGN laser, receiver andbrackets, making it an attractive upgrade for existing users ofROTALIGNand ROTALIGNPRO.

This handbook sets out to help the instrument user work through theinstrument with the required ease. It is meant to be a quick learningtool that hopefully should make compelling reading.

We welcome feedback so if anything is unclear, please let us know.

Ismaning, Germany February 2005

Foreword


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ntroducing ROTALIGN Ultra

Chapter 1: Introducing ROTALIGN Ultra

ROTALIGN Ultra Shaft package ALI 4.000

ALI 4.200 ROTALIGN Ultra

computer

including:

ROTALIGN Ultra

rechargeable

batteryALI 4.603

ROTALIGN Ultra stand

ALI 4.201

ALI 4.800 ROTALIGN Ultra case

Contents not included

ALI 3.610 Laser

including:

dust capALI 3.607

ALI 3.600 Receiver

including:

dust capALI 3.606

ALI 3.581-2 Receiver cable


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Introducing ROTALIGN Ultra

ALI 3.608 Adjustment tube

ALI 4.503 ROTALIGN Ultra USB / peripheral

devices cable

SYS 3.651 Battery charger

ALI 2.113 SET

Compact chain-type bracket

set

includes: ALI 2.114, ALI 2.115,

ALI 2.170, ALI 2.171, ALI 2.172,

ALI 2.173 and ALI 2.174

ALI 3.588 Tape measure mm/inch

Package items not shown include:

ROTALIGN Ultra READER licence certificate ALI 4.721

Lens cleaning cloth ALI 2.905ROTALIGN Ultra pocket guide ALI 9.844.G

ROTALIGN Ultra part 1 operating instructions ALI 9.845.G

ROTALIGN Ultra part 2 operating instructions ALI 9.846.G

Allen key (2.5 mm) 0 0739 1055

ALI 4.502-2 ROTALIGN Ultra USB cable

ALI 4.722 CDROTALIGN Ultra READER CD

(activation key label affixed)


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Safety notesROTALIGN Ultra is to be used in industrial environments only foralignment of turbine components, shafts, bores, measurement ofstraightness and flatness of different surfaces. Care must be taken toensure that the instrument is not subjected to mechanical knocks.ROTALIGN Ultra must be operated only by properly trained person-nel. No liability will be assumed when components or operatingprocedures as described in this manual are altered without permis-sion of the manufacturer.

Safety symbolsThe following symbols are used in this manual in order to draw thereader's attention to especially important text, such as that regardingpossible sources of danger or useful operating tips.

This symbol denotes general information and tips regardingoperation of ROTALIGN Ultra.

This symbol denotes information which must be followed in order

to avoid damage to equipment.

This symbol denotes information which must be followed in orderto avoid personal injury.

CE compliance and EMC

ROTALIGN Ultra fulfills the EC Guidelines for electric devices (73/23/EWG) and electromagnetic compatibility (EMC) (89/336/EWG).ROTALIGN Ultra has been tested to the scope of:

WARNING

CAUTION

Note

Laser safety

The ROTALIGN Ultra system uses a class II laser beam. Class II laserscomply with the requirements outlined in the USA's FDA specification21 CFR Ch. 1, Parts 1040.10 and 1040.11 as well as the ANSIstandard. It also fulfills British standard BS 4803 (Part 1 to Part 3)and European Industrial Standard IEC 825. The class II laser operates


EN 61326 Edition 2004-05 EN 61000-4-2 Edition 2001-12

EN 61000-4-3 Edition 2003-11 EN 61000-4-4 Edition 2002-07

EN 61000-4-5 Edition 2001-12 EN 61000-4-6 Edition 2001-12

EN 61000-4-11 Edition 2001-12 EN 55022 Edition 2003-09


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Do not look directly into the laser beam at any time. (Since FDAspecifications allow maximum exposure of 0.25 seconds, thenatural blink reaction of the human eye is normally sufficient toavert any danger, provided that no optical instruments otherthan ordinary eye glasses/contact lenses are used.)

Do not insert any optical devices into the beam path.

The red LED on the front of the transducer illuminateswhenever the laser beam is emitted.

WARNING

Getting to know the ROTALIGN Ultra computer

The ROTALIGN Ultra computer has been developed to effectivelyhandle both simple and complex shaft, bore and turbine diaphragmapplications. The computer is also used to carry out straightness and

flatness measurements. ROTALIGN Ultra has a customer-orienteduser interface. It uses easy-to-follow icons and comprehensive on-screen menus and hint texts, that even first-time users are able tooperate the computer without difficulty.

ROTALIGN Ultra is built to rugged industrial standards of shock andwater resistance. It contains a complete computer with a colour 480 x320 1/2 VGA display, oval-shaped function and data entry keys, 4-way navigation keys, an On/Off/Enter key, an up key, a clear key anda menu key.

Operating keys

Return/Clear/Menu keysOn/Off/Enter key

Data entry keys

Function keys

Navigation keys


at a wavelength of 675 nm, with a maximum pulse duration of128 s, maximum radiant power of 0.8 mW and maximum radiantenergy per pulse of 0.1 J. No maintenance is necessary to keep thisproduct in compliance with the specifications referred to.


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The navigation keys are used to navigate through the menu items.The 'Enter' key in the center is used to access any selected item.

The 'On/Off/Enter' key is used to perform the dual function ofswitching on ROTALIGN Ultra, and accessing any selected item. Toswitch on, press and hold the 'On/Off/Enter' key for approximately 5seconds.

The 'Up' key is used as a back/return key, taking user to previouslyselected function.

The 'Clr' (Clear) key is used to delete information entered inadvert-ently.

The 'Menu' key is used to call menu options related to the selecteddisplay screen.

The data entry keys are used to enter relavant data.

ROTALIGN Ultra possesses 3 function keys.

The 'Dimension' key is used to access machine set-up to define andenter machine dimensions.

The 'Measurement' key is used to enter the alignment measurementmode.

The 'Result' key is used to call alignment results into the display.

Power supply

ROTALIGN Ultra is powered using a 7.2 V 6.0 Ah Lithium-ionrechargeable battery ALI 4.603, which is to be charged only using thebattery charger SYS 3.651. This can be done with the battery insidethe computer. The computer may continue to be used if the battery ischarged inside it.Alternatively, use 6 standard 'C' size batteries contained in the batterycompartment ALI 4.605.

ROTALIGN Ultra top panel connectors

Charger socketThe red dot on the chargerplug must match the reddot on the battery socket

Sensor / RS232 socketEnsure correct ROTALIGNlaser cable plug orienta-tion to avoid damaging

pins

USB host/slave portThe red dot on the USBcable plug must match thered dot on the USB port



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Replacing batteries

The rechargeable battery ALI 4.603 and the battery compartment ALI4.605 have identical shapes and are therefore replaceable.If batteries require removal, turn over the computer taking care notto damage the display and the hard keys. Undo the two screws byturning them at least half a turn. With the screws loosened, lift and

pull the rechargeable battery or the battery compartment (dependingon power supply source) out. The reverse procedure is used to mountback the rechargeable battery or the battery compartment.

Lift compartment or

rechargeable batteryafter undoing thescrews

Replace compartment

or rechargeablebattery by sliding itinto the grooveappropriately


Connecting the batterycharger to ROTALIGN

Ultra The red lightnext to the batterysymbol on the keypadlights up when charg-ing takes place withthe system turned on

If you are using the standard 'C'size batteries, it is recommended toreplace all of them in one go. Notethe battery polarity when insertingthem in the compartment ALI 4.605.Due to similarity, the battery

compartment is removed andreplaced in the same manner as therechargeable battery ALI 4.603.

6 'C' size batteries

Battery compartmentALI 4.605


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Laser and receiverLaser ALI 3.610

The semiconductor laser diode emits a ray of red light (wavelength675 nm) which is visible where it strikes a surface. The beam isemitted with a diameter of approx. 5 mm (3/16"). Because the laseris operated in short pulses and not as a continuous beam, its power islow enough to qualify for Class 2 safety.

Do not stare into the laser beam!

Locking knob

On/Offtoggle switch

Vertical beam positionadjustment thumbwheel

"Beam active"indicator LED

Rubber housing

Horizontalbeam positionthumbwheel

Battery compartment

The beam is adjusted during set-up by changing its vertical andhorizontal angles with thumbwheels so that the beam strikes thereceiver lens straight on.

The laser is water and dust resistant. The internal optics andelectronics are internally sealed, preventing possible contamination,e.g. via the two thumbwheel slots.

The battery compartment is not watertight. If water enters thiscompartment, open it and dry it out. The battery should then bereplaced.

WARNING

CAUTION

Laser battery

The laser is powered by a single 9 V battery (type IEC 6LR61) which,depending on battery make and operating patterns, provides atypical operating duration of 80 hours. Lithium batteries of this sizecan also be used, increasing operation up to 150 hours. NiCadrechargeables may also be used.

Laser and receiver


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As the battery becomes depleted, the color of the 'laser active'indicator LED (see previous page) changes from red to yellow.When this occurs, the battery should be replaced.

CAUT

ION

PRFTE

CHNIKAG

D-85737I

SMAN

ING

Comp

liesw

ith21

CFR1040.10

and 2

1 CFR

1040.11

Opening

housing

causes

mis-

adjustm

ent a

ndvo

idswa

rranty

S/No

Type

Date

ofman

ifacture

D

URAC

ELL

ALKALINE

DURACE

LL

ALKALINE

M N1604

6LR61

9,0V

Note

The battery is replaced by removing both screws from the batterycompartment cover of the laser housing as shown above.

Under no circumstances may the four smaller housing screws beremoved, as that would result in misadjustment and would voidall warranty coverage.

Be aware that when NiCad rechargeable batteries are used asreplacements, their voltage tends to drop quite rapidly as theybecome depleted. This may limit the effective warning time (seenote above), so a fully-charged spare should be held in reserve.

Used batteries should be disposed of in an environmentally-soundmanner!

CAUTION

Note

Receiver ALI 3.600

The receiver contains two position detectors, located one behind theother, which measure the exact position of the laser beam as theshafts are rotated. The detectors are biaxial, analog, photoelectricsemiconductor position detectors with a resolution of better than1 m / 1/1000 mm (or 0.04 mils) and an area of 18 mm x 18 mm /

0.7" x 0.7". The receiver also contains an electronic inclinometerwith resolution better than 2 for shaft rotation measurements.

Laser and receiver


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The receiver has two indicator LEDs on its front side, one green andthe other red, to indicate beam adjustment.

RedLED

GreenLED

Scratch-resistant lens

Lockingknob

Rubberhousing

Cablesocket

The laser beam is out of the posi-ion detector range and both theed and green LEDs are blinking

very fast.

The laser beam is at the edge of theposition detector and both the redand green LEDs are blinking fast.

Laser and receiver


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The laser beam lies in the positiondetector measurement range. Thered LED is off while the green oneblinks slowly.

The laser beam lies at the center ofthe position detector measurementrange. The red LED is off while thegreen one blinks slowly.

The receiver is powered by the ROTALIGN Ultra computer via a cable(ALI 3.581-2) through which measurement data also pass.

Cable connection

Insert the angled plug into the receiver socket as shown; note thekeyway indicating proper plug orientation. Screw down the cablefitting to tighten the connection. The angled plug should be leftpermanently connected to the receiver, even when storing the systemin its case, as this will help avoid damage to cable pins, plugs and

sockets.

Laser and receiver


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Never turn the plug itself, as that can damage the cable pins!

Note correct plug orientation indicated by the markings on theplug and the socket.CAUTION

Laser and receiver


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Chapter 2: Using ROTALIGN Ultra

Press to switch on the computer

Press and hold the 'On/Off/Enter' key for about 5 seconds. Theopening screen below appears.

Use the navigation keys to access available applications. The naviga-tion direction is either upwards/downwards or sideways.

Available applications and options

The following applications and options can be selected via theprogram manager applications screen.i) Shaft alignment used to position the centerlines of rotation of

two (or more) machinery shafts in line with each other.ii) Soft foot starts the soft foot wizard which assists in correcting

soft foot.iii) Templates used to select a specified template for a new

measurement job.iv) Device configuration used to configure the ROTALIGN Ultra

computer settings. When this option is selected, the followingcomputer settings can be configured: date and time, language,units, power management, printer set-up, device info, displayand sound, owner info, and users' list. The option is also used toenable PC communication, open the license manager, start theword completion function, customization, and to change users.

v) Flange machine used to configure flanged machines.

vi) Pump-gearbox-motor used to configure a pump/gearbox/motor assemblyvii) Pump-motor with spacer used to configure a pump/motor

assembly coupled using a spacer shaft.

Available applications

Icons with a green upwards arrowindicate self-created templates orfiles.


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Configuration

viii)Pump-motor used for standard pump/motor combinations.ix) Turbine-gearbox-generator used to configure a turbine/gear-box/generator assembly.

x) Turn off used to turn ROTALIGN Ultra off.

ROTALIGN Ultra configuration

Setting date and time

Accessing this section allows you to set the current date and time,choose the proper time zone, and change the date and time

presentation formats.

Use the navigation keys to selecttem to be changed. To change digitvalues press followed by theupward navigation key to increasevalue or the downward key todecrease value.

To change the presentation format,press . Use the upward/down-ward navigation key and highlightFormat' from the context menuhat appears. Press . The screen

opposite appears.

A drop down menu is available forhe selection of time zones.

The navigation keys are used tohighlight format that requires to behanged. Press and a drop

down menu listing available

ormats appears. Confirm selectedormat by pressing


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Language selectionAccessing this section allows you to select preferred country lan-guage.

Use the upward/downward naviga-tion key and highlight preferredlanguage. Press to confirmselection.

Setting unitsAccessing this section allows you to change the units and precision ofphysical quantities used in ROTALIGN Ultra.

Use the navigation keys to selectitem requiring setting. Press ,and highlight required unit fromthe drop down menu that appearsusing the upward/downwardnavigation key. Press to confirmselection.

Configuration


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Different system units can be configured pressing while in theunit screen. The context menu appears.

Use the upward/downward naviga-ion key and highlight preferredystem of units. Press to confirmelection.

Power management

This section displays the current battery status allows you to controlthe power management features of shutdown, hibernate (sleepmode), and standby.

To set standby and hibernate

modes, press . Highlight re-

quired mode from the drop downmenu that appears using theupward/downward navigation key.Press to confirm selection.

Configuration


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Printer set-upAccessing this section allows you to set-up printers and the printingconfiguration on ROTALIGN Ultra.

Select printer by pressing , andhighlighting required printer fromthe drop down menu that appearsusing the upward/downwardnavigation key. Press to confirmselection.

Use the navigation keys to scroll through the settings and print

options. Press to select or edit an option or setting.

More printing options can be accessed by pressing while in theprint screen. The context menu appears.

Scroll the context menu using theupward/downward navigation key.Press to confirm selection.

Other printing preferences such aspage size, pages per sheet, pageorientation and paper source can beset under properties.

Configuration


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Device infoAccessing this section allows you to see the current file space andoperating memory statistics, the CPU data, the ROTALIGN Ultraserial number, and information about the core software used in thedevice.

ROTALIGN Ultra

erial number

Configuration


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Display settingsAccessing this section allows you to change the contrast andbrightness of the display screen.

The contrast is changed using / .The display brightness is adjustedusing / .

Word completion

The word completion mechanism helps save keystrokes and timewhile typing. It also helps you to make sure no properties aremisspelt. When a user begins the entry of a word already listed in thesystem dictionary, the word is completed automatically.

The word completion screen dis-plays choice of words available forthe automatic completion mecha-nism.

To add, delete or test the completion mechanism, press . Thescreen overleaf appears.

Configuration


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Use the upward/downward naviga-ion key and highlight actionequired from the context menuhat appears. Press and use thecreen that appears below to enter

new word or word to be tested.

Use the data entry keys to enterwords. When entering letters, is

used to enter blank space.

New words are stored in the systemdictionary by pressing and thenhighlighting 'Accept changes' usingupward/downward navigation key,and finally pressing . Alternative-y, enter new word and then press

.

Configuration


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CustomizationCustomization makes it possible to change the device settings suchthat the information displayed and the appearance of the display aresuited to one's individual usage.

'Customization options' screen is accessed via the program manager.Start the program manager and use the navigation keys to select'Device configuration'.

Press to access 'Device configuration'. The screen below appears.

Use the navigation keys to select 'Customization'. Access the 'Custom-ization options' by pressing .

Configuration


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Select item to be customized byhighlighting the respective itembox using the navigation keys.

Press and use / to select

desired setting from the drop downmenu that appears. Confirm setting

by pressing either or .

Options available include:

Right menuThe context menu item labels can be displayed as icons, text captionsor both. The drop down menu reveals the following options:

Text and icons both icons and text are shownText only only text caption is shownIcons only only icons are shown

Keyboard backlitTwo options are available - backlit is set either off or in normal use

Status bar hintsTwo options are available - normal use and never

BeepThe internal beeper can emit sound signals when specific tasks takeplace. The drop down menu reveals the following options:

Never beeper is permanently off.System events only the sound signal is emitted only when a systemevent occursEvery key stroke the sound signal is emitted when a system eventoccurs and each time a button is pressed

Resume policyThis option is useful for the resume functionality of ROTALIGN Ultra.The drop down menu reveals the following items:

Resume files manually a new job is started by loading a defaulttemplateAlways resume last file the most recent job resumes automatically

Configuration


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Global index styleTwo options are available - use full screen index and use title barindex

The global style index shownopposite is the title bar index. This

type of index appears when is

pressed at any time, and 'Index'selected from the context menuthat appears.

The global style index shownopposite is the full screen index.

This type of index appears whenis pressed at any time, and

'Index' selected from the contextmenu that appears.

Configuration


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Context menu itemsUseful menu items can be accessed via the context menu that appearswhen is pressed at any time. 'Help' provides substantial onlinehelp and 'Index' is used to access a wide range of items that includeaccessing the program manager, turning the computer off andconfiguring the instrument.

Context menu items available fromhe program manager configurationcreen.

Context menu items available fromhe set-up screen.

Configuration


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Tips and tricks Pressing long enough opens the global menu.

Pressing for approximately 3 seconds prompts the turn offsystem dialog.

Pressing for approximately 7 seconds resets the system.

Press to zoom out the image.

Press to zoom in the image.

Pressing either or long enough moves the view of the train tothe right or left respectively.

Pressing the corresponding data entry key moves the view to therespective coupling position (observe inset in display).

Pressing either or moves the view of the train to the rightor left respectively.

While in the program manager, the data entry keys are used toselect the corresponding application icon in a numerically ascend-ing order.

While in the program manager, and are used to change thescreen contrast.

When in set-up and units are set to Imperial system, entering adimension as 11.3.8 corresponds to 11 3/8 in.

Pressing while in set-up prompts the deletion of the selectedmachine.

When selecting type of machine the orientation of the machinecan be altered by pressing either or .

Pressing twice while in set-up zooms the machine train outand in again.

Pressing twice activates auto measurement.

Pressing and holding on, while in results, cycles the resultsbetween vertical (V), horizontal (H) and both H&V.

When entering data, pressing cycles through the charactersthat can be entered, and pressing 1 long enough enters the value.

Tips and tricks


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A

ALI 2.113 SET 1-5ALI 2.905 1-5ALI 3.581-2 1-4

Receiver cable 1-4ALI 3.588 1-5ALI 3.600 1-4

Receiver 1-11ALI 3.606 1-4ALI 3.607 1-4ALI 3.608 1-5

Adjustment tube 1-5ALI 3.610 1-4

Laser 1-10ALI 4.000 1-4ALI 4.200 1-4

ROTALIGN Ultra computer 1-4ALI 4.502-2 1-5

ROTALIGN Ultra USB cable 1-5ALI 4.503 1-5

ALI 4.603Rechargeable battery 1-8

ALI 4.605Battery compartment 1-8battery compartment 1-9

ALI 4.721 1-5ALI 4.722 CD 1-5ALI 4.800 1-4

ROTALIGN Ultra case 1-4

B

'Bad angle' 1-12

Batteriesreplacing 1-9

Bracketscompact chain-type 1-5

C

C size batteries 1-9Cable

connection 1-13CE compliance 1-6Clear key 1-7Components

Laser 1-10Laser battery 1-10Receiver 1-11

ConfigurationContext menu items 2-12Customization 2-9Date and time 2-2Device info 2-6Display settings 2-7Language selection 2-3Power management 2-4

Printer set-up 2-5Units 2-3Word completion 2-7

Context menu 2-5Customization options 2-10

D

Data entry keys 1-7

F

Function buttons 1-7, 1-8Function keys 1-7, 1-8

I

Index 2-11

L

Laserclass II 1-6

laser active 1-11Laser battery 1-10'Laser centered 1-13laser class II 1-6'Laser end' 1-12

'Laser OK' 1-13Laser safety 1-6LEDs 1-12Lithium-ion 1-8

M

Menu key 1-7

N

Navigation buttons 1-7Navigation keys 1-7, 1-8New words

storing 2-8testing 2-8

Index

ndex


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Index

O

On-Off-Enter key 1-7Operating elements 1-7Operating keys 1-7

P

Plug orientation 1-14

Power supply 1-8Program manager 2-1

R

Rechargeable battery 1-8Resume 2-10ROTALIGN Ultra computer

Settings 2-1switch on 2-1

S

Safety symbols 1-6

Serial number 2-6Sleep mode 2-4SYS 3.200 1-4SYS 3.521-2 1-5SYS 3.651 1-5

Battery charger 1-8SYS 3.801 1-4SYS 9.414.G 1-5

T

Thumbwheel 1-10Time zone 2-2Tips and tricks 2-13

U

Up key 1-7, 1-8


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PRFTECHNIK Alignment SystemsOskar-Messter-Strae 15D-85737 Ismaning, Germanywww.pruftechnik.comTel: +49 (0)89/ 99616-0Fax: +49 (0)89/ 99616-100eMail: [email protected]

Printed in Germany ALI 9.845.02.05.G

ROTALIGN, LEVALIGN, NOVALIGN and smartSCANNERare a registered trademarks of PRFTECHNIK Dieter Busch AG.PRFTECHNIK products are the subject of patents granted and

rotalign ultra system manual

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