OPTALIGN smart RS5 ®

Operating handbook – Shaft alignment

A user’s handbook

Dear Customer,

Welcome to precision laser shaft alignment using OPTALIGN® smart RS5. This OPTALIGN
smart RS5 handbook sets out to help the user work through the measurement system
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 December 2014
Part number DOC 12.205.en
Firmware version 3.xx

OPTALIGN® smart RS5 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 2014 by PRÜFTECHNIK Alignment Systems GmbH
 OPTALIGN smart RS5 handbook

Foreword
OPTALIGN smart RS5 is a precision shaft alignment system that combines the proven
OPTALIGN smart computer with the technical capabilities of a new and faster 5-axis
technology sensor. This powerful wireless communication laser alignment system is
used in most industrial environments. The computer with its ergonomic design and
intuitive operation is user-friendly. It features an alphanumeric keyboard with strategi-
cally 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 RS5 sensor contains two XL HD position sensitive detectors (PSD) and incorpo-
rates Micro Electro Mechanical Systems (MEMS), making it possible to monitor live,
horizontal and vertical machine corrections concurrently, and with the sensor at any
shaft rotational position. During shaft rotation, in Continuous Sweep, more and finer
readings are taken faster. This ensures highly repeatable results even under mechani-
cal constraints such as backlash.

OPTALIGN smart RS5 possesses powerful features that include among others, user-
definable stationary feet, plain 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.

2
The ‘OPTIONAL’ icon is used in this handbook to highlight all optional system features
and items.

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

PRÜFTECHNIK Alignment Systems

August 2014
Ismaning, Germany
 Contents

Contents
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Chapter 1: OPTALIGN smart RS5 packages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 OPTALIGN smart RS5 package ALI 12.005-RS5 ................................................................ 5
1.2 ALI 12.005-RS5R – OPTALIGN smart RS5 package with
rechargeable battery computer .............................................................................................. 8

Chapter 2: System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1 Safety notes..................................................................................................................... 9
2.2 Operating information................................................................................................... 10
2.3 Handling precautions..................................................................................................... 14

Chapter 3: OPTALIGN smart RS5 – an overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.1 Description.................................................................................................................... 17
3.2 Power supply................................................................................................................. 18
3.3 RS5 laser and sensor ..................................................................................................... 20
3.4 Mini compact chain-type bracket ALI 2.118................................................................... 23

Chapter 4: Getting started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.1 Set up OPTALIGN smart RS5........................................................................................... 25
4.2 Set RS5 sensor as default............................................................................................... 26
4.3 Enter dimensions........................................................................................................... 27
4.4 Wireless measurement................................................................................................... 28
4.5 Results........................................................................................................................... 31
4.6 Context menu items...................................................................................................... 33

Chapter 5: Horizontal machine alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5.1 Preparing for the alignment procedure .......................................................................... 35 3
5.2 Check for soft foot........................................................................................................ 36
5.3 Mount the brackets ...................................................................................................... 36
5.4 Mount Bluetooth module, RS5 sensor and laser ............................................................ 38
5.5 Switch the computer on and start application................................................................ 40
5.6 Enter machine dimensions............................................................................................. 40
5.7 Machine set-up.............................................................................................................. 43
5.8 Flipping machines.......................................................................................................... 63
5.9 Laser beam adjustment.................................................................................................. 65
5.10 Take measurements..................................................................................................... 70
5.11 Results......................................................................................................................... 72
5.12 Rotating machine view................................................................................................. 80
5.13 Align machine.............................................................................................................. 81
5.14 Saving data and printing.............................................................................................. 90
 OPTALIGN smart RS5 handbook

5.15 Quick check measurement........................................................................................... 95

5.16 Soft foot...................................................................................................................... 97
5.17 Checking and correcting soft foot conditions............................................................... 98
5.18 Checking pipe strain.................................................................................................. 104

Chapter 6: Alignment features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

6.1 Measurement modes................................................................................................... 109
6.2 Distinct measurement features..................................................................................... 112

Chapter 7: Special alignment applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

7.1 Machine train alignment.............................................................................................. 119
7.2 Cardan drive machines................................................................................................. 129
7.3 Vertical and horizontal flanged machines..................................................................... 138
7.4 Measure...................................................................................................................... 144
7.5 Results......................................................................................................................... 145
7.6 Machine alignment...................................................................................................... 148

Chapter 8: Configuration and data management. . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

8.1 Shortcut numbers........................................................................................................ 151
8.2 Configuration.............................................................................................................. 151

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Updating OPTALIGN smart RS5 to a newer firmware version.............................................. 171
Suggested shaft alignment tolerances................................................................................ 176
OPTALIGN smart RS5 technical data................................................................................... 178
Declaration of Conformity.................................................................................................. 180

Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

4
 OPTALIGN smart RS5 packages

Chapter 1: OPTALIGN smart RS5 packages

ALI 12.005-RS5 is the standard OPTALIGN smart RS5 package.

For details of other available OPTALIGN smart RS5 stand-alone and add-on pack-
ages, please contact your local PRÜFTECHNIK sales representative.

All optional items and features are highlighted in this handbook using the
 Note

‘OPTIONAL’ icon.

1.1 OPTALIGN smart RS5 package ALI 12.005-RS5

ALI 12.805 OPTALIGN smart RS5 case

ALI 12.200 OPTALIGN smart RS computer including

batteries

ALI 12.600 OPTALIGN smart RS battery housing Nicht

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ALI 12.201 Computer stand pas

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1 ALI 12.600

OPTALIGN® smart RS

ALI 12.805 ALI 12.200 ALI 12.201

 OPTALIGN smart RS5 handbook

ALI 3.900 RS5 sensor

ALI 3.910 RS5 laser

ALI 3.981-2 Sensor cable, 2 m

ALI 4.621i Bluetooth module

ALI 3.905-0.28 Bluetooth module cable

ALI 12.502-2 PC cable for OPTALIGN smart RS computer

ALI 3.900 ALI 3.910 ALI 4.621i

ALI 3.981-2 ALI 12.502-2 ALI 3.905-0.28

 OPTALIGN smart RS5 packages

ALI 12.503 USB cable for peripherals

ALI 4.451 USB memory stick

ALI 2.118 Small chain-type bracket [Note that the

OPTALIGN smart RS5 package contains 2
no. ALI 2.118]

ALI 12.701 OPTALIGN smart shaft

firmware certificate [not shown]

ALI 2.905 Lens cleaning cloth

ALI 3.588 Tape measure mm/inch

7
ALI 12.503 ALI 4.451

ALI 2.905 ALI 2.118 ALI 3.588

 OPTALIGN smart RS5 handbook

DOC 12.105.en OPTALIGN smart RS5 pocket guide

DOC 12.205.en OPTALIGN smart RS5 operating

handbook

DOC 12.905.en OPTALIGN smart RS5 product catalogue

[not shown]

ALI 13.700 CD ALIGNMENT CENTER CD

DOC 12.105.en

DOC 12.205.en

ALI 13.700 CD

1.2 ALI 12.005-RS5R – OPTALIGN smart RS5 package with

rechargeable battery computer

The standard items in this package are the same as those in ALI 12.005 -RS5 but in this
8
package, the OPTALIGN smart RS computer ALI 12.200 is powered using a recharge-
able battery ALI 12.601. In addition, the package features the OPTALIGN smart RS
charger ALI 12.651-I (universal).

ALI 12.601 OPTALIGN smart rechargeable battery

ALI 12.651-I OPTALIGN smart charger [universal]

2
0001 12.601
ALI
1.00

ALI 12.601 ALI 12.651-I

 Safety notes

Chapter 2: System description

2.1 Safety notes

OPTALIGN smart RS5 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. OPTALIGN smart RS5 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.

2.1.1 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

OPTALIGN smart RS5. HNote

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

damage to equipment.
a
s
CAUTION

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

personal injury.
WARNING

This laser safety warning symbol denotes laser radiation.

9
Numbers in red circles indicate the corresponding operating step described in
1
these instructions and must be performed exactly.

2.1.2 CE compliance and electromagnetic compatibility

OPTALIGN smart RS5 fulfills the EC Guidelines for electric devices and those relating
to electromagnetic compatibility as indicated in the conformity certificate attached in
the appendix. The certificate may be downloaded from the PRÜFTECHNIK website.

2.1.3 IP classification
The computer is dust-tight and protected against water jets (IP65). Both the sensor
and laser comply with code IP67 (dust-tight and protected against immersion).
 OPTALIGN smart RS5 handbook

2.1.4 Laser safety

The OPTALIGN smart RS5 system uses a Class 2 laser. This laser complies with the
requirements of IEC/EN 60825-1 and 21 CFR 1040.10 and 1040.11 with laser notice
No. 50. The laser operates at a wavelength of 670 nm and has a maximum radiant
power <1 mW. No maintenance is necessary to keep the product compliant as
outlined above.

 Do not look directly into the laser beam at any time. (The natural blink
reaction of the human eye is normally sufficient to protect the eyes from
any dangers posed by looking at the laser beam briefly. But as natural blink
s
WARNING
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 LED on the front of the laser illuminates whenever the laser beam is
emitted.
 CAUTION – Use of controls or adjustments or performance of procedures
other than those specified herein may result in hazardous radiation
exposure

2.2 Operating information

2.2.1 Temperature range

OPTALIGN smart RS5 and its related system components must be used at tempera-
tures between -10°C and 50°C (14°F to 122°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
10
60°C (-4°F to 140°F).

2.2.2 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 OPTALIGN smart RS5 and its related components to
reach the ambient temperature.
H Note
 Operating considerations

2.2.3 Incident light

Avoid exposing the system to strong, hot light such as direct sunlight.

2.2.4 Dust and water seals

The system computer is water and contamination 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 periodically checked. This can be carried out during
service and inspection of the system which is recommended to be carried out every
two years.

2.2.5 Interface connection

OPTALIGN smart RS computer is fitted with a single interface for the RS5 sensor, mains
supply as well as data exchange with a PC/printer.

2.2.6 Notes regarding data storage

With any data processing software, data may be lost or altered under certain

H
circumstances. PRÜFTECHNIK strongly recommends that you keep a backup or
printed records of all important data.
Note

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 11

functions, such as loss or alteration of stored data.

2.2.7 Disposal

Any waste electrical and electronic parts of the OPTALIGN smart RS5 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.
 OPTALIGN smart RS5 handbook

2.2.8 Component labelling

Labels used in communicating laser safety and other general information are to be
found on the system component housings affixed as shown below.

The laser beam hazard

symbol label is affixed at
the front of the RS5 laser
head.

CLASS 2 LASER PRODUCT

The laser safety warning
IEC 60825-1:2007
P<1mW, pulse<400µs, λ=630-680nm
Complies with 21 CFR 1040.10 and
label, the laser identi-
1040.11 except for deviations pursuant
LASER RADIATION to Laser Notice No. 50, dated June 24, 2007 fication label and the
DO NOT STARE INTO BEAM laser inspection label are
AVOID EXPOSURE
LASER LIGHT IS EMITTED FROM THIS APERTURE affixed to the back of the
RS5 laser ALI 3.910.

16

12

Located at the back of both The RS5 sensor identifica-

Type ALI 3.900
the RS5 sensor ALI 3.900 and tion label and the sensor
S.No. 3900 0100 16
the RS5 laser ALI 3.910 is the HWS 1.00 inspection label are
respective inspection label Date September 2014 affixed to the back of the
of manufacture Check calibration

(shown opposite in green – PRÜFTECHNIK AG RS5 sensor ALI 3.900.

85737 Ismaning
note that the white arrow www.pruftechnik.com
Made in Germany
points to the month when the
respective inspection is due.
The year is shown at the center
of the inspection label. In these
examples the next RS5 sensor
inspection due date is August
2016. And the RS5 laser is due
inspection in February 2016.
 Component labelling

This label is located at the

back of the OPTALIGN
smart RS computer
battery housing.

The OPTALIGN smart RS

Type S.No.
computer identification
label is located at the
bottom of the computer.

13
 OPTALIGN smart RS5 handbook

2.3 Handling precautions

OPTALIGN smart RS5 and its related components are precision instruments and should
not be dropped or subjected to physical shock.

2.3.1 Storage
Use the OPTALIGN smart RS5 case ALI 12.805 to transport OPTALIGN smart RS5 and
its related components. If the system is not used for an extended period, remove the
related batteries from the components and store the components in a cool, dry and
well-ventilated location.

Observe the storage temperatures and humidity specified in the technical data.

2.3.2 Care
a
CAUTION

All optical surfaces (laser aperture, sensor lens) must be kept clean. Use the supplied
lens cleaning cloth ALI 2.905. Avoid vigorous polishing to preserve the anti-reflective
coatings of the glass elements. OPTALIGN smart RS computer housing may be wiped
clean using a soft cloth dampened with a mild, non-abrasive detergent (use soapy
water with only 1% mild soap in water). The display should be cleaned using a soft
dry cloth.

2.3.3 Maintenance
Although the OPTALIGN smart RS5 system is essentially maintenance-free, the
following points should be observed:
 The accuracy of both the RS5 sensor and the RS5 laser should be checked every
two years as indicated by the coloured label (shown at right) located on the back 16
14
of their respective housings.
 Please return the system heads to your authorized PRÜFTECHNIK service center In the example above the
for inspection by the date indicated. inspection due date is
November 2016

a
When returning battery operated OPTALIGN smart RS5 system components to
PRÜFTECHNIK for inspection, service or repair, ensure that the batteries are not
defective. If you suspect a defect in the battery, DO NOT ship the unit with the
CAUTION
defect battery back to PRÜFTECHNIK. You may contact your local representative
for further information.
The relevant safety data sheets for all PRÜFTECHNIK Alignment Systems
batteries are posted on the PRÜFTECHNIK website at www.pruftechnik.com. The
packaging and dispatch regulations for any given battery are described under
paragraph 14 in the safety data sheets.
 Handling precautions

2.3.4 Disposal
Any waste electrical and electronics parts of the OPTALIGN smart RS5 system including
memory sticks must be disposed of according to applicable safety and environmental
regulations.
Customers in member states of the European Union must adhere to the EU directive
2002/96/EC on waste electrical and electronic equipment (WEEE). PRÜFTECHNIK
products that fall under this directive are marked with the shown crossed-out wheelie
bin symbol and must be disposed of according to this directive.
 The marked components must be disposed of with PRÜFTECHNIK or their
authorized disposal partners.
 Such parts must be taken to the nearest collection facility.
 If you have any questions regarding the WEEE Directive, please contact your local
PRÜFTECHNIK sales representative.

2.3.5 Transporting magnetic brackets and other magnetic components

To ensure that stray magnetic fields do not affect the avionics in aircraft, the
aviation industry has put forward stringent regulations for air transportation of
magnetic material. The magnetic field strength of such components must not exceed
specified limits. To comply with this regulation, a cover plate has been developed
for all PRÜFTECHNIK Alignment magnetic brackets and components that lowers the
magnetic field strength significantly, keeping it well below the required limits and
therefore causing no restrictions for air transportation. The relevant safety data sheets
are available for download and reference on the PRÜFTECHNIK website at www.
pruftechnik.com.

2.3.6 Attachments

H
Any amendments to the issued certificates will be posted on the official 15

PRÜFTECHNIK website – www.pruftechnik.com.

Note
Please visit the website on a regular basis for information on new and current
products.
 OPTALIGN smart RS5 handbook

Page intentionally left blank

16
 Introducing OPTALIGN smart RS5

Chapter 3: OPTALIGN smart RS5 –

an overview

3.1 Description

3.1.1 OPTALIGN smart RS computer keyboard at a glance

The computer possesses three 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 four functions – switching

OPTALIGN smart RS computer on/off, and accessing any selected item or
confirming an action. To switch on/off, press and hold e, the ‘On/Off/Enter’
key briefly.’

1 — The data entry keys are used to enter relevant machine data.
17


1 2 3 4 5 1. Alignment condition LEDs

2. USB port / Sensor socket /
Charger socket
3. Function keys [d, m, k]
6 4. Up / Clear / Menu keys
5. Navigation keys

7 6. On/Off/Enter key
7. Data entry keys
8. Wireless communication
OPTALIGN® smart RS indicator LED
9. Battery status LED

9 8
 OPTALIGN smart RS5 handbook

3.2 Power supply

The OPTALIGN smart RS computer ALI 12.200 is powered using six standard ‘AA’ size
alkaline batteries contained in the battery housing ALI 12.600.

The rechargeable battery OPTALIGN smart RS computer option is powered using a 7.2
V 2.4 Ah Lithium-ion rechargeable battery ALI 12.601 (optional), which is to be
charged only using the AC power supply/charger ALI 12.651-I. The battery can be
charged only inside the computer.

The batteries allow operation of up to 18 hours (25% active measurement, 25%

standby, 50% ‘sleep’ mode).

3.2.1 Replacing batteries

The rechargeable battery ALI 12.601 and the battery housing ALI 12.600 have
identical shapes and are therefore interchangeable. If batteries require removal, turn
over the computer taking care not to damage the display and the hard keys. Undo
the two quarter-turn screws by rotating them at least 90° (1/4 turn). With the screws
loosened, lift and pull out the rechargeable battery or the battery compartment
(depending on power supply source). The reverse procedure is used to reinstall the
rechargeable battery or the battery compartment.

Due to their similarity, the battery housing ALI 12.600 is removed and replaced in the
same manner as the rechargeable battery ALI 12.601.

Lift housing or rechargea-

18 ble battery after undoing
the screws
Replace compartment or
rechargeable battery by
sliding it into the groove
appropriately 6 ‘AA‘ size batteries

2
Battery housing
0001 12.601
ALI
1.00
ALI 12.600

Nicht
Nicht ins
May wiederFeuer
Ne explod werfen
pas aufladb
jeter e in !
au fire! Notar.
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recharg
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 Introducing OPTALIGN smart RS5

If you are using the standard ‘AA’ size batteries, it is recommended to replace all of
them together. Note the battery polarity when inserting them in the housing ALI
12.600.

Used batteries should be disposed of in an environmentally responsible manner

in accordance with applicable regulations!
m
If OPTALIGN smart RS computer is not in use for extended periods of time, a
month or more, the batteries should be removed from the unit.
a
CAUTION
3.2.2 Charging the battery
Connect the AC power supply/charger ALI 12.651-I to the computer interface
connection and to the mains supply.

Before charging, the rechargeable battery should be discharged as much as pos-

sible. To charge the battery from 0% to 100% capacity takes approximately 4
hours.
H Note

The computer’s battery status LED indicates the charging status of the battery. A
flashing red LED indicates that the battery is either defective or fully discharged. The
LED flashes green at initialization and during the charging process. A constantly lit
green LED denotes that the battery is fully charged.

3.2.3 Mounting and dismounting the universal adapter/charger plug

The universal OPTALIGN smart adapter/charger ALI 12.651-I comes with three different
regional plugs. The available plugs are for the Euro zone, the US and the UK. When
mounting or dismounting a plug, pay attention to the direction of the arrow on the 19

plug just above the pins, and the arrow on the latching nipple on the charger housing.
To dismount a plug, push the latching nipple in the forward direction [ 1 ] as indicated
by the arrow on it and hold, then push the plug to the right [ 2 ] as on the arrow on
the plug.
Latching nipple
1

2 The direction arrow

on the plug has the
inscription ‘OPEN’ marked
above it.
 OPTALIGN smart RS5 handbook

To mount a plug, push the latching nipple in the forward direction [ 1 ] as indicated
by the arrow on it then slip the plug into the protruding prongs and slide it to the left
until it latches.

3.3 RS5 laser and sensor

3.3.1 RS5 laser ALI 3.910

The RS5 laser is switched on by pressing its On/Off push button switch. The “beam
active” indicator LED lights red steady then blinks green slowly. The laser is switched
off by pressing and holding down On/Off push button switch until the LED turns off.
The semiconductor laser diode emits a ray of red light (wavelength 670 nm) which
is visible where it strikes a surface. The beam is emitted with a diameter of approxi-
mately 5 mm (3/16”). The laser is classified with a Class 2 safety rating.

Do not stare into the laser beam!

The beam is adjusted during set-up by changing its vertical and horizontal angles with
s
WARNING

thumbwheels so that the beam strikes the sensor lens straight on.
The RS5 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 two AA size batteries should then be replaced.
a
CAUTION

3.3.2 Laser batteries

20 The RS5 laser is powered using two high energy AA size alkali-manganese 1.5 V
batteries. These provide a typical operating duration of 180 hours.

As the battery becomes depleted, the colour of the ‘laser active’ indicator LED
changes from green (full) to yellow (half full) to red (empty). When this occurs,
the batteries should be replaced.
a
CAUTION

If the laser is not in use for extended periods of time, a month or more, the bat-
tery should be removed from the unit.

The batteries are replaced by undoing the quarter-turn screw on the battery
compartment cover by rotating it by at least 90° (1/4 turn). With the screw loosened,
lift the cover, and then use the red strap to remove the batteries. Replace both
batteries at the same time.
 Introducing OPTALIGN smart RS5

a m
 Under no circumstances may the two smaller housing hex head screws be
removed, as that would void all warranty coverage.
 Used batteries should be disposed of in an environmentally-sound manner!
CAUTION

RS5 laser ALI 3.910

“Beam active” indicator LED
Vertical beam position adjustment
thumbwheel

Rubber housing

Horizontal beam position

thumbwheel

RS5 laser dust cap in “open

position”
Laser emission
aperture
On/Off push button switch

Locking knob

Batteries are replaced 21

by undoing the 1/4 turn
screw and then opening
the battery compartment
cover. Pull the red battery
compartment strap to
remove the batteries.

/4 turn screw
1

Battery compartment cover

/4 turn screw
1
Strap
 OPTALIGN smart RS5 handbook

RS5 sensor ALI 3.900

Distance marking
Laser beam position LEDs

Rubber housing

Scratch-resistant lens

RS5 sensor dust cap in “open

position”

Cable socket

Locking knob

3.3.3 Opening the RS5 sensor/laser aperture

Opening the RS5 sensor or the RS5 laser aperture functions in a similar manner. In the
following example, images of the RS5 sensor are used.

22

Step 3: Lock the dust cap

in its “open position”
highlighted in red below.

Step 1: Lift the dust cap

slightly in the direction
shown by the bold red
Step 2: Rotate the dust cap
arrow.
in either direction as shown
by the bold red arrow.
 Introducing OPTALIGN smart RS5

3.3.4 RS5 sensor ALI 3.900

The sensor contains two position detectors, which measure the exact position of the Alternatively, if wireless
laser beam as the shafts are rotated. The sensor also contains an electronic inclino- communication is NOT
meter for shaft rotation measurements. used, the sensor may be
The sensor has two indicator LEDs on its front side, one green and the other red, to powered by the computer
indicate beam adjustment. via the sensor cable
The sensor is powered by the wireless communication Bluetooth module ALI 4.621i ALI 3.981-2 through which
via the Bluetooth cable ALI 3.905-0.28. measurement data will
also pass.
3.3.5 Service and care

The accuracy of the system components should be checked every two years as
indicated by the date wheel label (shown at right) located on the back of the
sensor housing.
H Note

Month
Please return the system to your authorized PRÜFTECHNIK service center for in-
16 Year
spection by the date indicated.

3.4 Mini compact chain-type bracket ALI 2.118

Compact and lightweight, this bracket is designed to provide extremely rigid support
for the measurement components with a minimum of mounting time and effort. The
chain-type bracket fits onto shafts and couplings ranging from 15 to 200 mm (19/32” to
7 7/8”) 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.

H
23

OPTALIGN smart RS5 package ALI 12.005-RS5 items are shown in section 1.1.
Note

Compact chain-type Optional magnetic bracket Optional magnetic sliding

bracket ALI 2.118 set ALI 2.761 SETIS bracket ALI 2.230
comprises 2 no. ALI 2.761
 OPTALIGN smart RS5 handbook

Optional compact magnetic Optional extra-thin bracket

bracket ALI 2.112 ALI 2.109 SET

H
When transporting any magnetic brackets and components from PRÜFTECHNIK
Alignment Systems, especially by air transport, please ensure that the magnetic
field strength of such brackets and components are kept well below the stipu- Note
lated limits by using the provided cover plate. The relevant safety data sheets
for different PRUFTECHNIK Alignment Systems magnetic brackets and other
magnetic components may be downloaded from the PRÜFTECHNIK website at
www.pruftechnik.com.

24
 Getting started

Chapter 4: Getting started

4.1 Set up OPTALIGN smart RS5

1. Prepare the machines by making certain that they are locked out, tagged out
and all necessary safety precautions have been taken.
Refer to section 5.4 for
2. Mount brackets, Bluetooth module, sensor, and laser. The sensor connected
details on mounting
to the Bluetooth module should be mounted on the right machine (usually
components.
movable). The laser is mounted on the left machine (usually stationary).
3. Switch OPTALIGN smart RS computer on by pressing e. The system beeps
followed by the flashing of an alignment condition LED. Shortly afterwards, the
machine dimensions screen appears.

RS5 laser mounted on RS5 sensor connected to

left machine (usually the Bluetooth module
stationary mounted on right
machine (usually movable)

25

OPTALIGN® smart RS
 OPTALIGN smart RS5 handbook

4.2 Set RS5 sensor as default

1. Press q twice to show the expanded menu, then use the f/g and
highlight ‘Configuration’.

2. Confirm selection by pressing e, and then use the navigation keys and
highlight the ‘Default settings’ icon.

26

3. Confirm selection by pressing e. The “Default settings” screen opens. Use

f/g and highlight the item ‘Default sensor’, and then press e to
confirm selection. A selection box with three different sensor options appears.
 Getting started

The type of sensor used

may also be set via the
“Dimensions” screen
context menu item ‘Change
sensor type’.

4. Use f/g and highlight the option RS5. Confirm selection by pressing
e.

4.3 Enter dimensions

Press d to access the machine dimensions screen.

Use the data entry keys to directly enter all required dimensions.

27

The editing box appears as soon as a data entry key is pressed. Confirm entry by
pressing e. The rectangular highlight box moves to the next dimension. The
navigation keys can also be used to cycle through all dimensions.
Dimensions to be entered include:

1. Sensor-to-coupling center
2. Coupling diameter (default is 100 mm / 10” {for US units})
3. RPM (default is 1500 / 1800 {for US units})
4. Coupling center-to-front foot (machine designated movable)
5. Front foot-to-back foot (machine designated movable)
 OPTALIGN smart RS5 handbook

4.4 Wireless measurement

Initially switch the RS5 laser on by pressing its On/Off push button switch. Open the Refer to section 5.9. for
RS5 laser aperture and then adjust the laser beam onto the RS5 sensor dust cap center details on laser beam
by repositioning the components vertically by moving them along the support posts, adjustment.
and horizontally by loosening the compact chain-type bracket.

RS5 laser

Avoid looking directly at the laser beam.

When the laser beam is centered on the RS5 sensor dust cap, tighten brackets and
s
WARNING

components.
Now press m to access the “Measurement screen”. When in “Measurement”
screen, press q then use f/g to highlight the context menu item ‘Sensor
selection’.

28
 Getting started

Confirm selection by pressing e. The selection window below appears.

Use f/g to highlight ‘Scan’ then press e to scan Bluetooth modules within
the neighbourhood.

Now make sure the Bluetooth module is switched on.

Once detected, the Bluetooth module is selected automatically.

H
Note

29
 OPTALIGN smart RS5 handbook

RS5 laser

Open the RS5 sensor aperture and then center the laser dot on target using the
two yellow fine adjustment thumbwheels. Position the laser dot at the center of
the target square or as near the center as possible. The blue OPTALIGN smart RS
computer alignment condition LED lights up and the green LED on the RS5 sensor
blinks slowly.

30

If using Continuous Sweep mode and Auto Sweep is on [set under the “Configura-
tion” screen item ‘Shaft settings’], measurement is automatically initiated when the
shafts are rotated. If Auto Sweep is set off, press e to initiate Continuous Sweep
mode.
Rotate the shafts through a complete turn or as far as possible. A minimum rotation
of at least 70° is required.
 Getting started

Press e to finish measurement.

4.5 Results

Press k to view alignment results.

The ‘all-in-one’ results

screen activated under
‘Shaft settings’ shows both
vertical and horizontal
coupling and foot results.

31

Coupling results are given in the form of gap and offset. Gap is positive when open
at the top or side away from viewer. Offset is positive when at the coupling point, the
shaft of the right machine is higher or further away from viewer.

Individual vertical and horizontal foot and coupling results are accessed by pressing
either k or f or g.
 OPTALIGN smart RS5 handbook

Vertical position results (

the ‘OK’ smiley indicates
alignment within tolerance
but can be improved by
aligning the machine to
obtain a happy smiley )

Horizontal position results

( a sad “smiley” indicates
alignment out of tolerance)

Both vertical and horizontal results show the foot position relative to the centerline of
machine designated stationary.
32 Positive values indicate that feet of machine designated movable are upwards or
away from viewer. Negative values indicate that feet of machine designated movable
are downwards or towards the viewer. The alignment condition is indicated by the
tolerance symbol and the corresponding lit OPTALIGN smart RS computer alignment
condition LED.

A happy smiley (with blue LED lit): values within excellent

tolerances

An “OK” icon (with green LED lit): values in acceptable

tolerances

A sad smiley (with red LED lit): values out of tolerance

 Getting started

4.6 Context menu items

A useful feature available in OPTALIGN smart RS computer is the availability of display

screen related context menu items for each individual screen. Useful menu items that
include accessing the “Configuration” screen to configure the computer, as well as
turning the computer off, can be accessed via the context menu that appears when
q is pressed at any time.
The context 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.
H Note

Context menu items are If using the shortcut keys

available for every screen. pressing 7 -> 2
In this example, the context prompts the ‘change train
menu items available from orientation’ hint.
the “Dimensions” screen
are displayed. To change
machine train orientation
from Horizontal to Vertical
highlight ‘Train orientation’
-> ‘Vertical train’.

33
Context menu items
available from the “Results”
screen
The item ‘Move’ is used to
prompt Live Move, which
may also be accessed
directly by pressing the
corresponding data entry
key 2.
 OPTALIGN smart RS5 handbook

This page intentionally left blank

34
 Horizontal shaft alignment

Chapter 5: Horizontal machine alignment

5.1 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! s
WARNING

5.1.1 Solid, flat foundation

A solid, rigid foundation is required to obtain correct, lasting shaft alignment that
allows long-term uninterrupted machine service.

5.1.2 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.

5.1.3 Rigid couplings

Rigid couplings must be loosened before measurement so that they do not distort the
alignment condition.

5.1.4 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!). 35
Because of the measuring principle, OPTALIGN smart RS5 can distinguish between
coupling backlash and misalignment. During shaft rotation, the laser beam must
however, strike the sensor detector during some portion of the rotation.

5.1.5 Soft foot

Soft foot causes the machine frame distortion every time the anchor bolts are
tightened, making proper alignment difficult or impossible. (Refer to sections 5.16
– 5.17 for details.)

5.1.6 Thermal growth, alignment targets, tolerances

These values can be obtained from the individual machine specifications, and then
entered into the program. (Refer to sections 5.7.2, 5.7.4 and 5.7.5 respectively for
details.)
 OPTALIGN smart RS5 handbook

5.1.7 Measurement separation

Since the system requires no mechanical connections (such as cantilevered dial Note: A maximum laser-
indicator brackets) to span over the coupling during measurement, alignment may sensor separation of 10 m
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.

5.2 Check for soft foot

Refer to sections 5.16 – 5.17 on soft foot.

5.3 Mount the brackets

H
OPTALIGN smart RS5 system is delivered with fully assembled brackets, and with
the RS5 laser, RS5 sensor and Bluetooth module already assembled. In this case,
the bracket holding the RS5 laser is mounted on the shaft on the left side of Note
the couplings or the solid coupling hub on the left side. The bracket assembly
holding the RS5 sensor connected to the Bluetooth module is mounted on the
shaft on the right side of the couplings or the solid coupling hub on the right
side.

Mount the brackets on either side of the coupling on either the shafts or on the solid
36 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
a
s
CAUTION
bracket configuration supplied by PRÜFTECHNIK Alignment (for example,
do not use support posts longer than those supplied with the bracket).
Contact your local PRÜFTECHNIK Alignment representative if longer support
WARNING
posts are required.

If the brackets have not been fully assembled, follow the mounting procedure in
sections 5.3.1 and 5.4.
H Note
 Horizontal shaft alignment

5.3.1 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.

H
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.

37

Anchor peg

1
3 4

2
 OPTALIGN smart RS5 handbook

5.4 Mount Bluetooth module, RS5 sensor and laser

1. Mount the Bluetooth module on the support posts of the bracket fixed on the
shaft of the right machine (usually moveable machine). The module clamps on
the support posts. It is recommended to slide the Bluetooth module all the way
down onto the bracket frame.
2. Mount the RS5 sensor on the same support posts as the Bluetooth module. The
yellow locking knobs should be loose enough to allow the sensor slide onto the
support posts. Lower the sensor as close to the Bluetooth module as possible.
3. Clamp the sensor onto the support posts by tightening the yellow knobs.

38

3
 Horizontal shaft alignment

4. Connect the sensor to the Bluetooth module using the Bluetooth module cable. The shorter 90-degree
5. Mount the RS5 laser on the support posts of the bracket fixed on the shaft of connector of the
the left machine (usually reference machine) – as viewed from normal working Bluetooth module cable
position. Ensure that the yellow locking knobs are loosened enough to let you is connected to the 8-pin
slide the housing onto the support posts. Ensure that the laser can pass over or sensor socket. The keyway
through the coupling and is not blocked. orientation should be
Both the RS5 sensor and laser should be at the same height, as low as possible, yet noted, and the knurled
high enough for the beam to clear the coupling flange. They should also visually sleeve of the connector
appear to be rotationally aligned to each other. screwed in until it is snug.
Make the final adjustments, loosening the brackets slightly if necessary, then rotating The longer 90-degree
them, and retightening. connector of the
Bluetooth module cable is

4 inserted into the four-pin

socket on the side of the
Bluetooth module with
a groove, matching the
red dot on the plug to
the groove on the socket
to ensure proper plug
orientation. .

In some cases, if the

coupling is large enough,
a coupling bolt can be
removed and the laser
beam shot through the
bolt hole, in order to
39
5
avoid protruding radially
beyond the coupling‘s
outer diameter (O.D.).
 OPTALIGN smart RS5 handbook

5.5 Switch the computer on and start application

Switch on the computer by pressing e. The system beeps followed by the flashing
of the blue LED. Shortly afterwards, the shaft alignment machine dimensions screen
appears.

5.6 Enter machine dimensions

Machine information and dimensions are entered using the grey data entry keys.

The required dimensions are entered directly using the data entry keys. With the
required dimension highlighted, enter dimension by pressing the appropriate data
entry keys. The editing box appears as soon as the first key is pressed.

40

Confirm the entered value by pressing e. The highlight advances automatically to

the next required dimension. Alternatively, any dimension can be accessed by using
the navigation keys.
 Horizontal shaft alignment

The dimensions to be entered vary according to machine and type of coupling. In a

standard horizontal alignment application enter dimensions as follows:

5.6.1 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.

5.6.2 Coupling diameter

The coupling diameter can be obtained by measuring the circumference of the
coupling and dividing the value by 3.142 (p).
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 dimension automatically.
The default coupling diameter (also referred to as the reference diameter) may be set
under the “Default settings” screen.

5.6.3 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.
Default RPM may be set under the “Default settings” screen.

5.6.4 Coupling center to front foot, machine designated movable

This is the distance from the center of the coupling to the pair of machine feet nearest
to the coupling on the machine designated movable. 41

5.6.5 Front foot to back foot, machine designated movable

 OPTALIGN smart RS5 handbook

5.6.6 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 in front of 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.

5.6.7 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

42

2 B

In the case shown, B>A

A
and C>A. This spacer shaft
situation is effectively
handled by OPTALIGN smart
RS5.
Spacer removed

C
 Horizontal shaft alignment

5.7 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 ‘Flip
machines’, ‘Horizontal
train’ and ‘Vertical train’
appears when the menu
item ‘Train orientation’
is highlighted. The
43
sub-menu items are
accessed using h ->
g/f.

The menu items are accessed by highlighting the respective item using f or g
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 machines, the context menu item ‘Delete machine will be included within
the listed menu items.)
 OPTALIGN smart RS5 handbook

‘Train orientation’ is used to flip machines (see ‘Flipping machines’ section 5.8)
or to select either a vertical or horizontal machine train orientation. For instance,
you may wish to select ‘Vertical train’ for vertical flange-mounted machines.
‘Change sensor type’ is used to allow measurement using ROTALIGN sensor or
OPTALIGN sensor.

5.7.1 Machine properties

The editing of specific machine parameters is possible only if the respec-

tive options have been purchased and licenced. Please consult your local
PRÜFTECHNIK Alignments Systems representative for details.
H
Note

In this handbook the ‘optional’ icon is used to highlight features not available in
the standard version.

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
 machine name

44

5.7.1.1 Editing machine type

To choose type of machine to be displayed, use f/g highlight the context
menu item ‘Choose machine type’ then press e to confirm selection. The ‘Machine
selection’ pane opens.
 Horizontal shaft alignment

Use f/g to scroll through the available machine type graphics. Following
machine graphics are available: pump, motor, gearbox and a generic standard
machine.
If you need to change the orientation of the machine graphic use i/h.

45

Parameters that can be

edited for moveable
machines include:
 fixation
 flange position
 thermal growth values
 type of machine
 machine name

Soft foot measurement can

also be carried out from this
screen.
 OPTALIGN smart RS5 handbook

5.7.1.2 Editing machine name

To edit the machine name, use f/g to highlight the context menu item ‘Enter
name’. Confirm selection by pressing e. The editing box appears and the machine
name may be edited.

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 edit the machine name.

5.7.2 Thermal growth

Thermal growth values can be entered only when the machine is defined as moveable.
To enter thermal growth values, highlight the context menu item ‘Thermal Growth’
using either f or g.

Note: To be able to enter

46 thermal growth values,
coupling target values
and dial gauge values, an
optional firmware module
is necessary. Please order
part number ALI 12.713
[Targets, Thermal Growth
and Dial Gauge Target
Input] to activate the
features.
Press e. The “Thermal growth” screen appears.
 Horizontal shaft alignment

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.

47

To enter values in the horizontal orientation, press q while in the “Thermal growth”
screen. The context menu as shown below appears.
 OPTALIGN smart RS5 handbook

Use f/g to highlight the context menu item ‘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.

Thermal growth values may be disenabled from the “Thermal growth” screen by
highlighting the tick [ ] then confirming selection by pressing e.

48

Alternatively, press q while in the “Thermal growth” screen. The context menu
appears.
 Horizontal shaft alignment

Alternatively, with the

context menu open, press
1 followed by 2 to
disenable thermal growth
values.

Use f/g to highlight the context menu item ‘Thermal growth’ then use h to
switch to the submenu pane. Highlight the submenu item ‘Disable’ using f/g
then confirm disenabling values by pressing e.

Thermal growth values may

be enabled from this screen
once again by pressing e.

49

5.7.3 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.
OPTALIGN smart RS5 may be used to calculate thermal growth compensation if no
other values are available. Thermal growth is calculated from the following factors:
material characteristics, expected temperature difference, and height of the shaft
centerline above the shim plane.
 OPTALIGN smart RS5 handbook

Thermal growth is calculated as follows:

1. Access the “Thermal growth” screen for the machine whose thermal growth
requires calculating as described previously.
2. Press q while on the screen. The context menu appears. Use f/g to
highlight the context menu item ‘Thermal growth calculator’.

3. Confirm selection by pressing e. The thermal growth calculator pane appears.

50

4. Use the navigation keys to highlight the ‘Material’ information box then press
e. A drop down menu appears.
5. Use f/g to highlight required type of material.
 Horizontal shaft alignment

6. 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 machine feet
to the shaft centerline is 70
cm. This gives a growth of
0.71 mm. 51

Pressing q with the thermal growth calculator pane open reveals the available
context menu items.

The thermal growth pane

context menu items may be
used as desired.
 OPTALIGN smart RS5 handbook

5.7.4 Coupling properties

Coupling properties are entered and edited in the same manner as machine properties.
Use the navigation keys to highlight the coupling.

With the coupling highlighted, pressing e reveals the coupling parameters that can
be edited.

Coupling parameters that

can be edited include:
 coupling targets
 user defined tolerance
values
 type of coupling [types
available are short flex,
52
cardan and spacer
shaft]
 sensor type option

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.
 Horizontal shaft alignment

5.7.4.1 Editing coupling targets

To enter coupling target values, use f/g to highlight the context menu item
‘Targets’ 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 entered values by pressing e.

5.7.4.2 Selecting coupling type

To select type of coupling desired, use f/g to highlight type of coupling
required from the menu.

The option ‘Change to

short flex’ does not appear
under the menu items as it 53
is the current setting. If the
current setting was either
‘spacer’ or ‘cardan’, the
item ‘Change to short flex’
would appear in the menu.

Press e to confirm selection.

 OPTALIGN smart RS5 handbook

Type of coupling selected in

this example is cardan.

If the coupling type selected is spacer shaft or short flex, it is possible to set the
coupling results format directly from the machine dimensions screen.
With the coupling highlighted, press e to reveal coupling parameters that may be
edited.

In this example, the selected

coupling type is ‘Spacer
shaft’ and therefore the
availability of spacer shaft
formats that may be used to
display coupling results.

54

Use f/g and highlight the item ‘Spacer format’.

If the coupling type was ‘Short flex’, then the item ‘Short flex format’ would
appear in the list. H
Note

Press e to confirm selection. The available spacer shaft coupling results formats are
displayed.
 Horizontal shaft alignment

Offset B / Offset A Gap B / Gap A

Total Gap / Offset at Total Gap / Offset at Alpha / Beta

Left Coupling Right Coupling

Total Angle / Offset at Total Angle / Offset at

Left Coupling Right Coupling
55

Coupling results formats for spacer shafts, short flex coupling and cardan shafts may
also be set under the configuration item ‘Shaft settings’.
 OPTALIGN smart RS5 handbook

5.7.5 User defined tolerances

It may be necessary to specify individual tolerances. These user defined tolerances
may either be “symmetrical” or “non-symmetrical”. In “symmetrical” tolerances, the
tolerance value for the horizontal and vertical planes are equal. In “non-symmetrical”
tolerance, the two planes have different tolerance values.
To set type of user defined tolerance to either “symmetrical” or “non-symmetrical”,
use the configuration item ‘Shaft settings’.

The “Shaft settings” screen

is accessed via the menu
item ‘Configuration’. To
set ‘Symmetrical’ or Non-
symmetrical’ user defined
tolerances, highlight the
item ‘User tolerance type’
e. Use
and then press
f/g to highlight
desired type and then
confirm selection by
pressing e.
With type of user defined tolerance selected, return to the “Dimensions” screen and
highlight the coupling and then press e. The coupling parameters are displayed.

The coupling parameters

context menu is displayed

56
by pressing e with the
coupling highlighted.

Note that the “User

defined tolerances /
Tolerance table “ screen
may also be accessed
Use either f or g to highlight the context menu item ‘Tolerances’ then press via the “Results” screen
e. The combined “User defined tolerances / Tolerance table” screen appears. context menu item
‘Tolerance table’.
 Horizontal shaft alignment

In this example, the

active tolerances are
the “symmetrical” user
defined values which have
already been defined.
The ‘user’ button in the
lower frame is yellow. The
system tolerance table
is deactivated as can be
seen from the grayed
The ‘user’ button
out smileys in the upper
frame.
To edit the user defined tolerance values, 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.

57

Confirm entry by pressing e.

If the set user defined tolerance type was “symmetrical”, then values would be
displayed for both horizontal and vertical planes.

In this example, the

active tolerances are the
“non-symmetrical” user
defined values. Gap and
offset values are for both
horizontal and vertical
planes specified.
 OPTALIGN smart RS5 handbook

The entered user defined values (for both “symmetrical” and “non-symmetrical”
types) 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 combined “User defined tolerances / Tolerance table” screen.

Note that the screen header toggles between “Tolerance table” and “User
defined tolerances”.
H
Note

Pressing f/g
toggles the cursor between
the two frames – “Tolerance
table definition” and “User
defined tolerance values”.

The context menu item ‘Disable tolerances’ may be used to deactivate both system
and user defined tolerance values.

58

The context menu items

‘Enable tolerances’ and
‘Disable tolerances’ toggle
depending on current
tolerance status.

Tolerances may also be directly enabled and disenabled from the “Tolerance table” or
“User defined tolerances” screen.
 Horizontal shaft alignment

If tolerances are already

disenabled, a “no” symbol
[ ] appears instead of
the tick [ ]. Tolerances
may be enabled directly by
highlighting and the
pressing e to confirm
selection.

To disenable tolerances directly, use the navigation keys and highlight the tick [ ]
and then confirm selection by pressing e.

5.7.6 Tolerance table

The “Tolerance table” screen may be used to display the suggested active
PRÜFTECHNIK Alignment Systems tolerance table.

While in the “Tolerance

table” screen, the
navigation keys may be
used to toggle between the
system and user defined
tolerance values.

59

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
a
CAUTION
(tighter) values.

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.
 OPTALIGN smart RS5 handbook

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.

60

 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 (refer to section 5.14.2 ‘Printing reports’).
 Horizontal shaft alignment

5.7.7 Entering coupling target values as dial indicator readings

Coupling target values given in terms of dial indicator readings can be entered into
OPTALIGN smart RS computer 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 in section 5.7.3.

When the context menu appears, use f/g and highlight ‘Targets as dial
gauge’ and the press e to confirm selection. This prompts 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.
H Note

61
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. Alternatively,
use the “Dial gauge set-up”
screen context menu to
select desired dial gauge
configuration.
Use the navigation keys to exit the header and cycle
through the required dimensions. Enter the required
dimensions.
 OPTALIGN smart RS5 handbook

Press ß to access the “Targets as dial gauge values” display then enter the dial
indicator values in the respective value boxes using the data entry keys and confirming
each entry by pressing e.

62

Press ß to display the target values, including any bracket sag amounts entered in
terms of gap and offset.
 Horizontal shaft alignment

The “Coupling targets” screen context menu may be used to disenable coupling
targets if desired.

The screen context menu is Targets may also be

accessed by pressing q. disenabled directly from
The context menu and the screen by highlight-
submenu items available ing the tick [ ] and
include: then confirm selection by
Enabling and disenabling pressing e.
coupling targets, and
entering coupling target
values as dial indicator
readings.

5.8 Flipping machines

If machines are installed such that access to the opposite side of the machines is
restricted, and there is need to designate the right machine as stationary, then the
flip function is used.

In this example, the

machine set has been
mounted next to a wall, and
the machine on the right is
stationary.
63

As the opening template in

the application dimensions
screen shows the stationary
machine on the left, the
flip function is used to
designate the machine on
the right as stationary.
 OPTALIGN smart RS5 handbook

Situations where the machine positions on screen require rearranging often occur
when using predefined machine templates or during set-up (as can be seen in the
previous illustration).
1. Press q while in the “Dimensions” screen, then use the navigation keys and
highlight ‘Train orientation’ -> ‘Flip machines’.

Note that once a

measurement has been
taken, the “Dimensions”
screen context menu item
‘Flip machines’ disappears
and the machine positions
cannot be switched around
again.

2. Press e to confirm selection. A “Flip machines” hint screen appears.

64

The hint reminds the user that the laser must always be mounted on the left
machine as viewed by the user, and sensor to coupling center distance must be
checked again.
H
Note

3. Press e or ß to confirm flipping machines.

 Horizontal shaft alignment

The pump which is the

stationary machine has now
been flipped to the right
hand side but still remains
the stationary machine.

4. Ensure the laser is mounted on the machine on the left, then check the distance
between the sensor to coupling center.

5.9 Laser beam adjustment Note: Refer to the illustra-

tions on the next page.
1. Open the RS5 laser aperture by lifting and the rotating the dust cap until it
rests in its “open” position. Switch the RS5 laser on by pressing its On/Off push
button switch. Leave the sensor dust cap on its “close” position.

Do not stare into the laser beam!

2. If the RS5 laser and sensor have been roughly positioned to each other during
s
WARNING

mounting (see section 5.4 – ‘Mount Bluetooth module, RS5 sensor and laser’),
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 65

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 RS5 laser to center the laser beam on the
sensor dust cap, and then open the RS5 sensor aperture by lifting and rotating
its dust until it rests on its “open” position.
 OPTALIGN smart RS5 handbook

Laser beam adjustment It is highly recommended

that before mounting
RS5 laser
the laser on its bracket,
1
both yellow adjustment
thumbwheels be brought
to the approximate center
of their travel range. This
will ensure that the beam
is emitted from the laser
as straight as possible
and not at an angle.
Also make sure both
2 3 brackets are rotationally
aligned to each other.
These precautions will
greatly facilitate the beam
adjustment process.
ON/OFF push
button switch

vertical
4
66 RS5 sensor

horizontal
 Horizontal shaft alignment

5.9.1 Establishing wireless communication

1. Switch the Bluetooth module on. The battery status LEDs blink for three seconds.
The module is now ready for operation.
2. Press m to access the OPTALIGN smart RS computer measurement screen.

3. While in the “Measurement” screen, press q then use f/g to

highlight the context menu item ‘Sensor selection’.

67

4. Press e to confirm selection. The selection window appears.

 OPTALIGN smart RS5 handbook

5. Use f/g to highlight ‘Scan’ then press e to scan Bluetooth modules

within the neighbourhood.

Now make sure the Bluetooth module is switched on

Once detected, the Bluetooth module is selected automatically.

68

6. If the laser beam has been correctly adjusted [as shown above right], you may
proceed with measurement as described in section 5.10.
 Horizontal shaft alignment

5.9.2 Centring the laser beam dot

If the laser beam is not centered, use the screen hints to center the laser beam on the
position detector.

‘Laser off’ displayed when Red

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 centered – red LED
is off and green LED blinks
slowly

To ensure that the laser beam is not only centered but also reasonably perpendicular,
the “Measurement” screen context 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 in
section 6.2.5.

69

The beam does not have to be exactly at the center of the crosshair, as this will

H
not affect measurement accuracy. However, maximum range for measurement is
available when the beam is well centered.
Note

Once centered, the RS5 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 section
6.2.1 ‘Extending the measurement range’).
 OPTALIGN smart RS5 handbook

5.10 Take measurements

Once the beam is centered, such that the laser dot on the display screen is at the center
of the crosshair and the blue OPTALIGN smart RS computer LED is lit, measurement
may be started. The standard measurement mode is the Continuous Sweep method.
If using Continuous Sweep and the function Auto Sweep is set on [set under the
“Configuration” screen item ‘Shaft settings’] measurement is automatically initiated
when the shafts are rotated. If Auto Sweep is set off, press e to initiate Continuous
Sweep mode.

For details on shaft

settings please refer to
section 8.2.7.

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 mode. Details on the other modes can be found in
section 6.1 ‘Measurement modes’.

Measurement mode Application

70
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 (uneven) rotation, situations with long
spans or severe misalignment that will readily
cause the beam to fall out of range

Static measurement Vertical machines (flange mounted or four feet)

 Horizontal shaft alignment

Rotate the shafts a full turn or as far as possible. A minimum rotation of 70° is required.
Remember not to touch
mounted components!
It is advised to turn shafts
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.
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. Whenever possible, shafts should be
rotated through as wide an angle as possible. If you press e to finish measurement
and collect data, a screen similar to the following appears.

The black lines in the

rotational arc indicate the
positions where readings
have been taken. In case
of vibration, switch to 71
Multipoint measure mode
(refer to section 6.1.1) and
a higher averaging (refer
to section 6.2.4).

Alternatively, view alignment results directly by pressing k once measurement is

completed.
 OPTALIGN smart RS5 handbook

5.11 Results

5.11.1 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.

This complete alignment

condition screen appears
only when the option
‘All-in-one results’ is
activated in the ‘Shaft
settings’ configuration
For details on shaft
menu. If not activated then
settings please refer to
the screen displays only
section 8.2.7.
coupling results. Foot results
may then be accessed by
pressing k/f/g.

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 is the distance between the two shaft centerlines at the transmission
plane of the coupling.

5.11.2 Sign convention

The following sign convention is used in the evaluation of alignment results, and
72 assumes that the viewer is standing in front of the machines as they appear on the
display.
Gap is positive when open at top or side away from viewer, and offset is positive
when at the coupling point, the shaft of the right machine is higher or further away
from viewer.
Both vertical and horizontal results show the foot position relative to the centerline
of machine designated stationary. Positive values indicate that feet of machine desig-
nated movable are upwards or away from viewer. Negative values indicate that feet of
machine designated movable are downwards or towards the viewer.

If all four coupling values are within tolerance [indicated by the smiley icon and
the green or the blue LED], you do not need to align the machines.
H Note
 Horizontal shaft alignment

If no in-house standards or specifications from the coupling or machine manufacturer

are available, the computer alignment condition LEDs and the smiley provides a
tolerance check based on standard industry norms. If the measured alignment falls
within acceptable tolerance, the green LED lights up. The blue LED lights up when
the measured alignment falls within excellent tolerance. The red or yellow 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
horizontally. The different views may be accessed by pressing k/f/g.

In this example, the cursor

at the highlighted foot
position but no foot values
are highlighted because
the left machine has no
fixation.

In this example, the left

machine is stationary but
has two feet fixation. The
highlight is at both the front 73
feet and the corresponding
foot value which in this case
is 0.00 mm.
 OPTALIGN smart RS5 handbook

5.11.3 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.

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 pair of feet.
The foot correction value
at the middle feet appears
in the box just below the
74
entered dimension.
 Horizontal shaft alignment

5.11.4 Results table

The results table lists a maximum of three coupling result entries for currently selected
set of machines. These three entries may include the current coupling results and the
two most recent coupling results. The entries are in chronological order with the most
recent result appearing at the bottom of the list numbered as current ( ‘Cur.’). The
oldest result appears at the top of the list numbered 1st.
The results table is accessed through the “Results” screen. Press q while 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.

You may use f/g

to highlight any one of the
listed coupling results. With
75
the results set highlighted,
pressing e displays the
measurement details. The
highlighted results set may
be deleted by pressing c.

Use f/g to scroll though the coupling results entries.

H
The individual results can not be averaged. Only the result listed as current [Cur.]
can be displayed on the “Results screen”. Should a measurement result listed
Note
as current [Cur.] be deleted, then the next recent measurement will be listed as
current and these results will be displayed in the “Results” screen.
 OPTALIGN smart RS5 handbook

The measurement details for each single results set may be displayed by highlighting
the results set using f/g then pressing e.
Alternatively, use the context menu item ‘Measurement details’. With the desired
results set highlighted, press q then use f/g to highlight the context menu
item ‘Measurement details’.

With ‘Measurement details’ highlighted, press e to confirm selection.

The measurement details

shown here have ensued
from a Continuous Sweep
results set. Note that the
standard deviation is also
displayed.
76
 Horizontal shaft alignment

5.11.5 Alignment condition

The ‘smiley’ symbol on the coupling results screen 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 section 5.7.4 ‘Coupling properties’).

Within excellent tolerance

Within acceptable tolerance

Out of tolerance

The computer LED system provides additional information on the tolerance status.

Tolerance

Within tolerance
Smiley

Happy face
Lit LED

Blue H Note

Within tolerance OK Green

Out of tolerance Sad face Amber

Worse tolerance Sad face Red

 The ‘smiley’ TAKES INTO ACCOUNT any targets and thermal growth values
which you may have entered – see pages 46 – 53.
H Note
77
 OPTALIGN smart RS5 handbook

The tolerance table is accessed from the “Results” screen. Press q to display the
context menu.

Use f/g to highlight the context menu item ‘Tolerance table’, then press e
to confirm selection. The “Tolerance table” screen appears.

78

If user defined tolerances are desired, use f/g to toggle between the recom- Usage of “Tolerance table/
mended tolerance table values and the user defined tolerance values. You may also User defined tolerance
use the “Tolerance screen” context menu item ‘User tolerance’ to switch to “User values” screen is explicitly
defined tolerance values” screen. described in sections 5.7.5
and 5.7.6
 Horizontal shaft alignment

With user defined tolerances now activated, press k to view alignment results.

The human bust icon next

to the smiley indicates
that the tolerances being
currently applied are user
defined tolerances.

79
 OPTALIGN smart RS5 handbook

5.12 Rotating machine view

The “Results” screen context menu item ‘Rotate view’ allows the user to view the
machines, and subsequently perform Move corrections from either side without
having to change the orientation of the OPTALIGN smart RS5 components.
This function is particularly helpful when the machines can be accessed from both
sides.
‘Rotate view’ functionality is available within the “Results” and “Move” screens.
After obtaining measurement results, press q then use f/g and highlight
‘Rotate view’.

With ‘Rotate view’ highlighted, press e to confirm selection. After confirming

selection, a video hint runs on the display.

80

When the video run stops, the orientation on the display changes to match the
opposite position. Results will now be displayed as currently viewed by the user. This
is from the opposite side of the original position.
 Horizontal shaft alignment

The screen on the left shows the initial orientation as viewed by the user, while the
screen on the right shows the orientation after the ‘Rotation view’ function has been
applied. In the screen on the right, the machine designated stationary is now on
the right hand side. Note that the vertical coupling gap values for both orientations
remains unaltered as are the horizontal coupling offset values. The applied sign con-
vention holds valid for both orientations.

H
Any applied ‘Rotation view’ functionality is temporary and is available only
in the “Results” and “Move” screens. As soon as one reverts to either the
Note
“Dimensions” or “Measurement” or “Soft foot” screens, the original machine
orientation is reassumed.

5.13 Align machine

H
Machines can be aligned using the given foot results by proceeding as described 81

below. Remember, if alignment is in tolerance (indicated by a happy smiley

Note
symbol and the blue or green system computer LED), there is NO need to align
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:
 OPTALIGN smart RS5 handbook

5.13.1 Shim first

H
It is recommended to perform vertical corrections first, since the horizontal
condition is easily affected by the process of loosening anchor bolts and inserting/
Note
removing shims, whereas the vertical condition is less prone to being affected
when performing horizontal moves. You may need to recheck soft foot before
proceeding.

5.13.2 Preparation and shimming

1. Prepare the machines for shimming by ensuring the following:
The foot bolts are clean, intact and removable.
Soft foot has been eliminated (refer to section 5.17).
The feet have enough shims under them should lowering the machine be
necessary.
Good quality shims such as PERMABLOC, MYLAR or LAMIBLOC are available
from PRÜFTECHNIK Alignment Systems. (Visit www.pruftechnik.com for details.)
2. Loosen foot bolts while trying to avoid moving the machine horizontally. If any
foot comes off the ground when loosened, suspect soft foot.
3. Use the vertical foot position values to shim BOTH front and back feet pairs 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.

82

4. 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.
H
Note
 Horizontal shaft alignment

5.13.3 Horizontal and vertical Live Move

The RS5 sensor technology allows Live Move corrections in both horizontal and
vertical directions concurrently with the sensor at any angular position.
H 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.

Use f / g to highlight ‘Move’ then press e to confirm selection. If Live

Move is initiated from the “all-in-one” results screen or the horizontal results screen,
the prompted Move direction will be Horizontal. Vertical Move direction may be
prompted by initiating Live Move in the vertical results screen.
If the laser beam is centered Live Move starts automatically. Proceed to carry out Live
Move in one direction (say Vertical shimming first) then in the other direction (say 83

Horizontal Move).
 OPTALIGN smart RS5 handbook

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
H
Note

beam has been centered.

5.13.4 Shimming using vertical Live Move

1. Having initialized Live Move from the vertical results screen, and the with foot
bolts of the ‘machine to be moved’ loosened, proceed to make the necessary
shimming corrections. Keep an eye on the smiley on the screen and the
computer alignment condition LEDs.

2. Use the vertical foot correction values to shim BOTH front and back feet pairs 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
84 suggest addition of shim thickness.

3. If the smiley returns a happy face or an OK symbol, the current vertical

alignment condition is within tolerance.
 Horizontal shaft alignment

5.13.5 Lateral positioning using horizontal Live Move

After making the vertical corrections, you may want to use the Live Move function to
carry out horizontal corrections.
1. Press q then use f/g to select ‘Change view’ followed by ‘Horizontal’.

2. Confirm selection by pressing e and proceed to carry out Live Move in the
horizontal direction.

85

3. 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.
4. Move the machine feet in the direction of the yellow arrows, keeping an eye on
the smiley on the screen. The arrows change with the movements automatically.
Watch the screen carefully to ensure that machine end and direction moved are
correct. The smiley on the display screen and the computer LEDs also give an
indication of the alignment condition as the machine is moved.
 OPTALIGN smart RS5 handbook

If desired you may toggle

between the Horizontal and
Vertical Live Move directions
using f/g.

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
a
CAUTION
moving machines.

5. If the smiley returns a happy face or an OK symbol, the current horizontal

alignment condition is within tolerance
6. Tighten anchor bolts and to proceed to verify alignment condition after Move.
7. Press q then use f/g to highlight ‘Stop’.

86

8. Confirm selection by pressing e.

 Horizontal shaft alignment

9. 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.

5.13.6 Saving data and printing

(See section 5.14.)

5.13.7 Finish alignment

Switch off the computer, the Bluetooth module and the laser, then remove the com-

s
ponents from the shafts and store them in the case.

Replace guards before you switch the machine back on.

WARNING
87
 OPTALIGN smart RS5 handbook

5.13.8 Points to observe during Live Move

1. Have shafts accidentally moved (rotated)?
The shafts, sensor and laser MUST remain steady during the entire Live 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.
H
Note

2. Extending measurement range

If the hint on the screen below appears during Live Move, then the laser beam has
drifted out of detection range due to great misalignment or long beam travel.

88

In this case, the measurement range can be extended as described in section 6.2.1.
 Horizontal shaft alignment

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 position on its own every time the
bolts are loosened and tightened. Correct this before aligning. (See section 5.16 for
details.)

4. If poor repeatability is experienced

Possible causes include:

›› Incorrect or loose bracket mounting

H
›› Significant shaft play or coupling backlash
›› Soft foot can cause positioning errors that make repeat measurement
Note
necessary
›› Loose anchor bolts
›› Yellow knobs on sensor or laser loose
›› Temperature changing: machines recently shut down?
›› Uneven shaft rotation
›› Shaft deflections from coupling strain

89
 OPTALIGN smart RS5 handbook

5.14 Saving data and printing

Before switching off the OPTALIGN smart RS computer, dimensions, measurements,

results and all settings can be saved for analysis, future use or record purposes in
the computer’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.

5.14.1 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.

Press e to confirm selection. The editing box appears.

90

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

5.14.2 Printing reports

Using the default printer type ‘PDF file’, measurement reports may be saved as a PDF
to the approved memory stick ALI 4.451 then printed off any Windows printer or
network printer without disconnecting or reconfiguring the printer.

Reports can also be printed directly from the OPTALIGN smart RS computer to a
printer.

To print the current measurement report, press q twice, then use f/g to
highlight ‘Print’.

Press e to confirm selection. The “Print report” screen appears.

Note: As may be seen

from the screen header, 91
the selected printer type
is the default – ‘PDF file’.
In this case, the report will
be saved as a PDF on the
approved memory stick
ALI 4.451.

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.
 OPTALIGN smart RS5 handbook

5.14.3 Configuring printer

If it is desired to print the report directly from the system, the printer settings must be
set accordingly. This can be carried out from the “Print report” screen. Press q and
use either f/g to highlight the context menu item ‘Printer configuration’.

Press e to confirm selection. The “Printer configuration” screen opens and the
printing settings are made. The settings may also be verified if unable to print meas-
urement report.
Alternatively, the “Printer configuration” screen may be accessed at any time as
described in section 8.2.6 ‘Printer configuration’.

5.14.4 Available printing options

The “Printer configuration” screen shows the options that can be selected.

92

Note: Currently set printer

type is the default – ‘PDF
file’.

Use either f/g to highlight the printer setting to be changed. The options
that are available are displayed by pressing e.
 Saving and printing

Use f/g to scroll

through the available
printers. Highlight a printer
and press e to confirm
selection or use ß to exit
the selection box.

The top-most printer type [in this case the default printer type – ‘PDF file’ – may be
selected by pressing 0.

Use f/g to scroll

through the available paper
sizes. Highlight the required
paper size and press e
to confirm selection or use
ß to exit the selection
box.

93

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 or use ß to
exit the selection box.
 OPTALIGN smart RS5 handbook

Use f/g to
select the colour in which
the report will be printed.
Selecting ‘Colour’ results
in full colour reports, while
‘GrayScale’ results in black
and white reports.

94
 Quick check

5.15 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 the user 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 RS5 sensor to
the Bluetooth module as described on section 5.4 [‘Mount Bluetooth module,
RS5 sensor and laser’].

2. Switch both the OPTALIGN smart RS computer and the Bluetooth module on,
then press m to establish wireless communication between the computer and
the sensor [for details refer to section 5.9.1]. If the laser beam has been centered
on the detector, turn the shafts in their normal direction of operation by at least
70°.

If however measurement
95

is finished by pressing
e, then pressing the
the results key k to
view foot results, a hint
screen appears requesting
3. After rotating the shaft by at least 70°, press the results key k. The missing diemnsions to be
“Dimensions” screen with missing dimensions opens. entered.
 OPTALIGN smart RS5 handbook

4. Proceed to enter the required dimensions.

Missing dimensions are

entered using the data
entry keys and confirmed by
pressing e.

96 5. Once all dimensions have been entered, the results screen appears.

The alignment results If however, the option

displayed depend on ‘All-in-one results’ has
whether the shaft setting not been activated
‘All-in-one results’ has in the ‘Shaft settings’
been activated. The screen configuration menu, only
opposite shows both the the sensor to coupling
coupling and feet results. center dimension needs
Use k/f/g to to be entered to display
cycle through the different coupling results.
results views.
 Soft foot

5.16 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, OPTALIGN smart RS5 is able to calculate, from shaft movement,
by how much each foot has moved as it is loosened.

97
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.
 OPTALIGN smart RS5 handbook

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.

5.17 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.

H
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
Note
middle feet loose and treat the machine as a four-footed machine. Soft foot is
measured only on machine designated as movable.

1. Set up the system in the normal way as described in sections 5.3 - 5.4, then
switch on the laser. Adjust the beam onto center of the sensor dust cap.
2. Open the RS5 sensor aperture by lifting and rotating the sensor dust cap to its
“open” position.
3. Switch the OPTALIGN smart RS 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.

The soft foot icon may be

used to directly access the
soft foot measurement
98
screen.

6. Use f/g to highlight the context menu item ‘Soft foot measurement’
then press e to confirm selection. The “Soft foot” screen may also be
accessed by using the navigation keys to highlight , then pressing e to
confirm selection.
 Soft foot

Now make sure the Bluetooth module is switched on.

7. If the laser beam is centered, the following “Soft foot” screen appears.
H
Note

8. Press e to continue with soft foot measurement ( proceed to step 8f).

If however, the laser beam is not centered, the following “Soft foot” screen
appears.

99

8a. Use the on-screen instructions to adjust the laser beam, or refer to section 5.9
‘Laser beam adjustment’.
8b. 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.
 OPTALIGN smart RS5 handbook

The context menu item

‘Adjust laser’ may also
be used to prompt the
on-screen instructions. With
the context menu displayed,
use either f/g
to highlight the context
menu item ‘Adjust laser’,
then press e to confirm
selection.

8c. With context menu item ‘XY view’ highlighted, press Full description of ‘XY
e to access the “XY view” screen. View’ may be found in
section 6.2.5.

100
8d. 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.
 Soft foot

8e. 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.
H
Note

Use f/g to
highlight ‘Yes’, confirming
selection by pressing e.
The dimensions screen
opens, and missing values
may be entered.

8f. After all required dimensions have been entered, the soft foot screen opens
automatically. Proceed with soft foot measurement.
9. Use the navigation keys to select the foot to be measured. Press e to confirm
foot selection. Loosen the corresponding anchor bolt.

101

10. The calculated distance that the foot has moved 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.
11. Repeat this procedure for each foot. Cycle through using the navigation keys if
required.
 OPTALIGN smart RS5 handbook

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.
The “Soft foot” screen context menu items may be used to carry out the displayed
functions.

The context menu items

‘Clear all SF measurements’
and ‘Pipe strain wizard’
toggle depending on
whether soft foot values are
available or not.

102
 Soft foot

5.17.1 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.

5.17.2 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.
103

a 0.18 0.89 b a 0.18 0.13 b

c 0.74 0.10 d c 0.76 0.10 d

 OPTALIGN smart RS5 handbook

5.18 Checking pipe strain

The effects of pipe strain on shaft alignment can be measured using OPTALIGN smart
RS5. 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.

5.18.1 How the function works

After mounting the laser, sensor and Bluetooth module as usual (refer to sections 5.3
-5.4), 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’ appears.

104

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
selection by pressing e.
 Pipe strain

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 Bluetooth module. Make sure that
both the laser and the Bluetooth module are switched on. You may refer to sec-
H Note

tions 5.4.

With the ‘Next’ button highlighted, press e to proceed with measurement. The
measurement screen appears.

If the laser beam is not

q
centered, press
then use g/f
to highlight the context
menu item ‘Adjust laser’, 105
confirming selection
by pressing e. After
adjusting the laser
beam press e or
ß to proceed with
measurement.

Rotate the shafts over a wide enough measurement range. When a wide enough
measurement range is attained, the ‘Stop’ button appears.
 OPTALIGN smart RS5 handbook

With the ‘Stop’ button highlighted, press e to finish the first measurement. The
instruction to loosen pipe flange bolts then appears.

106
After loosening the pipe flange bolts, press e with the ‘Next’ button highlighted.
This prompts the start of the second measurement step.
 Pipe strain

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.

107

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 section 5.14
‘Saving data and printing’.

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.
H
Note
 OPTALIGN smart RS5 handbook

This page intentionally left blank

108
 Measurement modes

Chapter 6: Alignment features

6.1 Measurement modes

In addition to the standard ‘Continuous Sweep mode’, OPTALIGN smart RS5 also
offers Multipoint and Static 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
‘Sweep’). The choice depends on the measurement mode required.

Note: The default The default measurement

measurement mode may mode is effective only
be set via the Configura- when a new file is
tion menu item ‘Default opened. Auto-resumed
settings’. Changing the files are opened with the
measurement mode from last used measurement
the “Measurement” screen mode.
does not change the set
default mode but changes
only the measurement
mode used within the
opened measurement file.
Press e to confirm selection.

109
In this case, the selected
measurement mode,
Multipoint is now active.
 OPTALIGN smart RS5 handbook

6.1.1 Multipoint measurement

Note: To be able to carry
This mode is used to measure shafts which are either difficult to turn continuously
out measurements using
or allow measurement only in certain rotational positions. The method can also be
Multipoint measurement
used to measure uncoupled shafts, nonrotatable shafts, sleeve bearings, white metal
mode, an optional
bearings and journal (radial) bearings.
firmware module is
necessary. Please order
After centering the laser beam as described in section 5.9 ‘Laser beam adjustment’,
part number ALI 12.715
press e to take the first measurement point. Rotate shafts in their normal direction
[Multipoint] to activate
of operation from one measurement position to the next, pressing e to take
this feature.
measurement. Measurements must be taken in at least three positions over at least
70° 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 the
taken measurements are
the minimum required to
obtain results; however, it is
recommended to obtain a
green arc for even greater
accuracy and quality of
After finishing measurement, press k to display readings.
results.
110

6.1.2 Static measurement

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

After centering the laser beam as described in section 5.9 ‘Laser beam adjustment’,
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 For horizontally oriented
level or protractor. shafts, the optional
external inclinometer
Use the navigation keys to position the clock hour hand to the corresponding shaft ALI 5.020 may be used.
position.
 Measurement modes

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 (red cursor line) on the display
screen to the corresponding 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.
H
Note

Measurements must be taken in at least three positions over 90°, but it is recommended
to take more measurements over a wider angle. Eight is the maximum number of
points that may be taken over 360°.

111

After finishing measurement, press k to display results.

 OPTALIGN smart RS5 handbook

6.2 Distinct measurement features

6.2.1 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 ‘Infinirange’
function can be used.

H
The ‘Infinirange’ option is available only in ‘Multipoint’ and ‘Static’ measurement
modes.
‘Laser end’ is displayed when the laser beam falls out of the detector’s useful Note
linearized measurement range. ‘Laser off’ is displayed if the beam is blocked or
falls entirely outside the detector area. This situation 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 ‘Infinirange’ option. Use
g/f to highlight ‘InfiniRange’.

112

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.
 Extend measurement range

CAUTION! Do not allow

shafts to turn during this
process.

3. Readjust the beam into the target circle using the yellow laser emitter
adjustment thumbwheels.

113
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.
 OPTALIGN smart RS5 handbook

5. Continue measurement as before, rotating the shafts and pressing e to take Note: The ‘Infinirange’
measurements at the desired positions. beam readjustment
procedure (steps 1 – 5)
The program includes the displacement of beam readjustment in its alignment cal- may be repeated as often
culations. as necessary to obtain
sufficient measurement
6.2.2 Remeasuring points or rotational arc to
The possibility to remeasure is provided in all measurement modes. To remeasure, complete a set of readings
the current measurement needs to be stopped. To stop a measurement, press q successfully. This allows
while carrying out measurement. Use g/f to highlight the context menu item even very gross misalign-
‘Stop’. ment or very long spans
across spacer shafts to be
handled with ease.

Note that the context menu

item ‘Stop’ is available only
after a measurement has
been started.

Confirm selection by pressing e.

To start a new measurement, press q and use g/f to highlight the context
114
menu item ‘Start’.

The context menu item Note: The context menu

‘Start’ is available only item ‘Measurement
before a measurement is details’ which may also be
started. accessed via the “Results
table” context menu
appears only when the
measurement is valid.
 Resume/Averaging

A different measurement mode can also be selected under ‘Measurement mode’

before starting to remeasure.

Confirm selection by pressing e.

6.2.3 Resume
OPTALIGN smart RS5 provides the possibility to turn off the computer during
measurement and resume with the last file opened. On switching the computer 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, use the context menu item
‘New file’ which is accessible from any screen. The ‘Resume last file’ action is possible
only from the dimensions screen

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’ 115

(see section 8.2.1 ‘Device settings’), remains the active file when the instrument is
switched on again.

6.2.4 Averaging
In certain industrial conditions, it may be necessary to increase the number of
measurements to be averaged when taking readings to attain the desired accuracy.
Particular cases include applications with increased machinery vibration. An increased
averaging also improves the accuracy when measuring sleeve bearings, white metal
bearings and journal bearings.
 OPTALIGN smart RS5 handbook

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’.

Confirm selection by pressing e.

116

The average setting can be changed from a minimum averaging of 0.5 seconds to a
maximum averaging of 10.0 seconds.

H
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
Note
OPTALIGN smart RS5 enough time to ‘catch-up’ as the machine is 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 measurement has
been started.
 XY View

6.2.5 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 are rotationally aligned.
The option ‘XY View’ can be activated to help meet the requirement mentioned
above.
q while in the measurement screen. Use
To access the “XY View” screen, press
g/f to highlight the context menu item ‘XY View’.

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
117

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.
 OPTALIGN smart RS5 handbook

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” screen context menu
item ‘Absolute coordinates’.

118
If the laser beam dot is adjusted while in the “Relative mode” screen, it traces a path
showing the laser dot movement:

The new absolute positions

are ‘5.6, -0.2’ and
‘5.7, -0.1’.
 Machine train alignment

Chapter 7: 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 three machines coupled together)
 Cardan drive machines
 Flanged machines (mounted vertically or horizontally)

7.1 Machine train alignment Note: To measure the

alignment conditon of
7.1.1 How to align machinery trains three-machine trains, an
The following step-by-step approach is recommended for three-machine trains. optional firmware module
1. Measure alignment at each coupling is necessary. Please order
2. Display results and optimize corrections (by defining ‘stationary’ machine feet) part number ALI 12.723
3. Align two machines (remount laser and sensor if necessary) [3-Machine Train] to
4. Recheck alignment results activate this feature.
5. Align the two machines at the next coupling and repeat alignment check

7.1.2 Machine train set-up

Machine train set-up resembles the set-up described on pages 43-46 and will therefore
be outlined here only briefly.
1. While in dimensions screen, use the navigation keys to highlight either machine
then press q. The context menu with the menu item ‘Add last machine’
appears.
119

2. 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.
 OPTALIGN smart RS5 handbook

3. Configure the machine train as appropriate.

The train elements

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

120
Use h/i to highlight
machine to be edited.
Pressing e reveals the
corresponding submenu.
 Machine train alignment

7.1.3 Measurement
1. Use h/i to select the coupling to be measured.
2. Ensure the laser is mounted on the left side of the selected coupling.
3. Remove the dust cap from the laser and switch it on. Leave the sensor dust cap
on.
4. Press m and adjust the beam onto the sensor (refer to section 5.9 ‘Laser beam
adjustment’).
5. Proceed to carry out measurement as described in section 5.10 ‘Take measure-
ments’, observing the requirements for valid measurement — shafts must be
rotated by at least 70°; a minimum of 3 measurement points to be taken.

In this example, coupling

1 is measured using the
Multipoint measurement
mode. Measurement is
q
stopped by pressing
then using f/g to
highlight the context menu
‘Stop’. Press e to confirm
selection.

6. If using Continuous Sweep measurement mode, press e to stop measurement.

If the measurement mode used is not Continuous Sweep, measurement is
stopped by pressing q then using f/g to highlight the context menu
item ‘Stop’, and confirming selection by pressing e. 121

Pressing e with the

context item ‘Stop’ high-
lighted stops measurement.
 OPTALIGN smart RS5 handbook

7. Switch the RS5 laser off and mount the laser and the RS5 sensor across the next
coupling.
8. 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
measurement mode. In
this case, measurement is
stopped by pressing e.

H
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, since you might not replace the sensor bracket in exactly the same Note
location each time.
Always make sure the coupling you are measuring is the one actually highlighted
in the machine train.

9. Repeat the measurement procedure as described previously at the second

coupling position.
122

7.1.4 Evaluating results

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 A and B. In
this example, the option
‘All-in-one results’ is
activated in the ‘Shaft
settings’ configuration
menu. If not activated then
the screen displays only
coupling results.
 Machine train alignment

Vertical feet and coupling

values at the coupling
position between machines
A and B

Horizontal feet and coupling

values at the coupling
position between machines
A and B

Entire machine train

overview with vertical
123
feet and coupling values
between machines A and B
 OPTALIGN smart RS5 handbook

Entire machine train

overview with horizontal
feet and coupling values
between machines A and B

Press and hold i/h to jump to the next coupling in the train.

Jumping from one coupling position to the next is carried out from results screen
depicting two machines only. When in the results overview screen, jumping from
one coupling to the next is possible only when the cursor is on either foot postion
H
Note

of the middle machine.

Vertical and horizontal feet,

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

124

Vertical feet and coupling

values at the coupling
position between machines
B and C
 Machine train alignment

Horizontal feet and coupling

values at the coupling
position between machines
B and C

Entire machine train

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

Entire machine train

overview with horizontal
125
feet and coupling values
between machines B and C
 OPTALIGN smart RS5 handbook

7.1.5 Move corrections

After deciding on which pair of machines to move in a train, one may need to reinstall Machine pair to be
and readjust the laser and sensor across the chosen coupling. Be sure to install the moved can be selected in
sensor at exactly the same location on the shaft or coupling as previously, or reenter “Dimensions” or “Results”
the new correct distance from the sensor to the coupling. screens by pressing h/i
Correction of misalignment may be carried out using the Live Move function. While in long enough.
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.

126

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.
 Machine train alignment

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 Live Move results. Jack
bolts on the feet or other mechanical or hydraulic devices are recommended for
a
CAUTION
moving machines.

127

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’.
 OPTALIGN smart RS5 handbook

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.

H
128
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
Note
out another measurement.

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.
 Cardan drive machines

7.2 Cardan drive machines

This section describes the aligning of cardan shafts using the cardan shaft bracket
lite ALI 2.874 SET iS used in conjunction with OPTALIGN smart RS5. Cardan drives
are installed and operate with a large offset between the driver and the driven shaft.
The cardan 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 electronically-con-
trolled 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 OPTALIGN smart RS5.

7.2.1 Mounting the faceplate to the rail

1. Slide the the faceplate down the rail as shown in 1 below. The four T-nuts
should sit in the grooves.
2. After positioning the faceplate on the rail, tighten the four socket head screws
using the provided M5 allen key [ 2 ].

129

1 2
 OPTALIGN smart RS5 handbook

3. 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
shown [ 3 ] in order to separate the bracket faceplate from the coupling face.

The coupling shown

opposite has a raised
face flange. The provided
spacers are used to create
a three-point plane to
ensure that the faceplate
and the coupling face,
3 which is the reference
surface are joined
Reference surface
together.
(Without the spacers, there would be no 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 center part of the coupling face must not be used as a reference surface.
H Note

7.2.2 Mounting the laser holder assembly on to the rail

1. Loosen the handwheel slightly, then slide the laser holder assembly down the
center groove of the rail, with the T-nut acting as a guide [ 1 ].

130

RS5 laser holder

1
 Cardan drive machines

7.2.3 Mounting and adjusting the RS5 laser

In this step, the laser beam is adjusted such that it is roughly colinear to the rotational
axis of the laser holder assembly.
1. Slide the two black distance sleeves down the support posts.
2. Slide the RS5 laser onto the posts until it rests on the distance sleeves [ 2 ].
3. Mark a set of target crosshairs on the shaft rotation centerline of the other
machine coupling (if the flange has a center hole, a temporary target surface
may be affixed to the hole).
4. Switch on the RS5 laser and adjust the beam to strike the center of the target on
the opposite coupling:
›› The objective is to adjust the laser beam such that it is roughly colinear to the
rotational axis of the laser holder assembly; this will make it possible to make
fine adjustments to the laser holder assembly’s position afterwards, without
having to realign the laser beam itself.

The distance sleeves (black) influence the offset by positioning the laser beam on
the same axis as the rotational axis of the laser holder assembly. H
Note

›› The two yellow beam position thumbwheels are used to adjust the angular
position of the laser beam. By rotating the laser assembly holder, the laser
beam traces an ‘approximate’ circle. If the ‘approximate’ circle is a single dot
at the center of the target, then the laser beam has been adjusted correctly.
If that is not the case, repeat the laser beam adjustment process until the
‘approximate’ circle corresponds to a single dot position.

131

Distance sleeve
(black)
 OPTALIGN smart RS5 handbook

RS5 laser adjustment tip:

H
If the beam describes a circle rather than a dot at the target when rotating
the laser holder assembly, then note how big the circle is and use the yellow
adjustment thumbwheels to move the laser beam back by half the distance it
Note
has moved when rotating the laser holder assembly 180° from its start position.
Do this both vertically and horizontally. When correctly adjusted, you should be
able to rotate the laser holder assembly a full 360° without the laser dot moving
from the target center.

As soon as a single dot position has been achieved, do not touch the laser
position thumbwheels. H
Note

132
 Cardan drive machines

7.2.4 Adjusting the RS5 laser beam to machine’s rotational axis

In this step, the laser holder assembly is adjusted on the bracket such that the laser
holder rotational axis is colinear with the rotational axis of machine to be aligned
(which could be a motor or a gearbox).

During this procedure, DO NOT touch the yellow laser beam position
thumbwheels.
H
Note

1. Carry out the vertical and horizontal adjustment of the laser holder assembly
by sliding it horizontally through the bracket rails and positioning it vertically by
rotating the bracket (see 1 below).
2. Repeat the above procedure until the laser beam strikes the center of the target
placed on the rotational axis of machine to be aligned.
3. Once the laser beam has been centered on the target, tighten the faceplate on
the coupling face using the provided hexagon socket head screws.

7.2.5 Positioning RS5 laser and mounting RS5 sensor for measurement
In this step, the RS5 laser is remounted on the underside of the laser holder while the
RS5 sensor is mounted on the shaft of the machine to be aligned.
1. Switch off the RS5 laser then remove it from its holder.
2. Using the provided M4 Allen key, loosen the support posts then slide them
through the laser holder base so that they protrude from the other side (see 2
below).
3. Retighten the M4 Allen screws to secure the support posts, then remount the
RS5 laser onto the support posts.

133

2
Laser dot

1
 OPTALIGN smart RS5 handbook

4. Use the chain-type bracket or appropriate magnetic brackets to mount the

Bluetooth module ALI 4.621i and the RS5 sensor ALI 3.900 on the shaft of the
machine to be moved (for instance the motor or gearbox) – (see 3 below).
5. Switch the RS5 laser on The RS5 sensor is aligned to the RS5 laser by pushing or
sliding the bracket supporting the RS5 sensor (see 3 below).

Do not touch the RS5 laser or its laser position thumbwheels.

7.2.6 Set-up and measurement

H Note

1. Switch the OPTALIGN smart RS computer on, and then proceed to set up the
machines (refer to ‘Machine set-up’ section 5.7). Select ‘Change to cardan’ in
coupling properties (refer to ‘Coupling properties’ section 5.7.3).
2. Enter all required machine dimensions.

Note: The cardan

shaft coupling type is
an optional firmware
module. Please order
part number ALI 12.718
[Spacer shaft] to activate
the feature.

134

3
 Cardan drive machines

3. With the RS5 sensor aperture open, press m and establish wireless communi-
cation (refer to ‘Wireless measurement’ section 4.4’). The laser beam location
should be apparent in the adjustment screen.
4. 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 ‘Multipoint measurement’ section 6.1.1.)

Note: The Multipoint

measurement mode is
an optional firmware
module. Please order
part number ALI 12.715
[Multipoint measure
mode] to activate the
feature.

5. Press e to confirm selection.

6. The laser dot should be in the square target. If not, center laser beam (refer to
‘Laser beam adjustment’ in section 5.9).

135

7. With laser beam centered, press e to take the first measurement point.
8. Rotate the RS5 sensor to the next measurement point.
9. Rotate the laser holder and the RS5 laser and observe the detector view in the
measurement screen (see next screenshot): at the moment when the laser dot is
positioned on the Y-axis, press e to take the next measurement.
 OPTALIGN smart RS5 handbook

10. Repeat steps 8 and 9 to take measurements in at least three positions over at
least 70° of rotation. (Taking more position measurements improves the reliability
of results.)
11. When enough measurement points over at least 70° rotation have been taken,
Alternatively, stop
press q then use f/g to highlight the context menu item ‘Stop’.
measurement by pressing
Confirm selection by pressing e to stop measurement.
q followed by 3.

136

7.2.5 Evaluation and alignment

Since offset does not affect the performance of cardan shafts, only angularity is
displayed for correction.
1. Press k to view alignment results.
 Cardan drive machines

Note that the angularity

is displayed in degrees
or mrad depending on
the ‘Angle format units’
selected under ‘Shaft
settings’ in the ‘Con-
figuration’ menu (refer to
section 8.2.7).

2. Cycle through the feet results using k/f/g. If a specific amount

of offset between the
machine shafts was
desired and the laser
holder assembly was set
up to this precise offset
as described in step 2
(section 7.2.2) previously,
then, after the angular
alignment of the movable
machine is completed,
remount and readjust
the laser as described in
steps 1–5 (section 7.2.3)
and proceed to adjust 137
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.

3. If the machines are out of tolerance, reposition them with the help of the Move
function (refer to sections 5.13.3 – 5.13.5).
4. Remeasure to determine the new alignment condition.
 OPTALIGN smart RS5 handbook

7.3 Vertical and horizontal flanged machines

A typical vertical machine arrangement comprises 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. OPTALIGN
smart RS5 calculates the shimming thickness for each flange bolt. Offset is corrected
by positioning the flange laterally.

7.3.1 Set-up

Before commencing with this section, please acquaint yourself with chapter 5
‘Horizontal machine alignment’.
H
Note

The RS5 laser and sensor (including Bluetooth module) 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, on vertically oriented machines, measurements
must be taken using Static measurement mode. The eight 45° measurement positions
used with this procedure must be marked accordingly on the machine.

7.3.2 Marking measurement positions

1. Mark a reference position on the bearing 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.
138
2. Measure the circumference of the shaft and divide by eight.
3. 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.

The shaft is numbered

counterclockwise looking
down the shaft, starting 0:00 4:30

at 0 followed by the clock 1:30 3:00

positions 1:30, 3:00, 4:30,

6:00, 7:30, 9:00 and 10:30.
 Vertical flanged machines

For circular housings, measure the circumference of the bearing housing and divide by
eight. Use this distance to make eight evenly-spaced marks on the housing beginning
at your chosen start point. Number the points clockwise looking down onto the shaft
with 0 as the first, followed by 1:30, 3:00, 4:30, 6:00, 7:30, 9:00 and 10:30. (Refer
1:30
to the diagram opposite.) 9:00
0:00
10:30

7.3.3 Mounting components and selecting machine orientation

1. Mount the RS5 sensor which is connected to the Bluetooth module, and the RS5
laser on either side of the coupling, ensuring that they are aligned exactly with
the 0 or reference mark.
2. Switch OPTALIGN smart RS computer on by pressing e.
3. From the dimension screen that appears, press q. With the context menu
displayed, use the navigation keys to highlight ‘Train orientation’ > ‘Vertical
train’.

139

4. Confirm selected train orientation by pressing e. A hint appears requiring the

acknowledgement of the change. Use f/g and highlight ‘Yes’ and then
press e to acknowledge change.

7.3.4 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:
1. With MTBM highlighted press e then use g to highlight “Change to
flange”.
 OPTALIGN smart RS5 handbook

2. 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
keys.

140 3. To edit the flange pattern, press q while in the ‘Flange edit’ screen. Use the
menu items ‘Flange shape’ and ‘Predefined bolt settings’ to edit the flange.
The following flange patterns are available:
›› Circular flange
›› Square flange – circular bolt pattern
›› Square flange
4. Highlight the menu item ‘Flange shape’ using g/f. This displays the
flange pattern submenu items. With the submenu items displayed, press h to
access the flange pattern pane.
 Vertical flanged machines

While in the pattern

pane, use f/g
to highlight required
flange pattern, confirming
selection by pressing e.

5. 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.

141

›› ii) When the context menu appears, press 4.

The option of selecting

predefined bolt positions
is currently possible with
circular bolt patterns only.
 OPTALIGN smart RS5 handbook

›› iii) Confirm bolt pattern selection by pressing e.

7.3.5 Enter dimensions

Press ß or d to return to the dimensions screen.
1. Enter the coupling center-to-sensor distance.

2. Enter the coupling diameter. The default is 100 mm (or 10” depending on unit
and language settings).

142

3. Enter the coupling center-to-flange distance.

 Vertical flanged machines

4. Enter the RPM. The default is 1500. (1800 if units option is set to US units.)

The flange configuration can also be edited from the above screen by highlight-
ing the flanged machine then pressing e.
H Note
143

To edit the flange configura-

tion, use g to highlight
‘Edit flange’ then confirm
selection by pressing e.

Measurements can now be taken.

 OPTALIGN smart RS5 handbook

7.4 Measure

1. Press m and then establish wireless communication between the RS5 sensor
and OPTALIGN smart RS computer ( refer to ‘Wireless measurement’ in section
4.4).

For vertically oriented machine trains, Static measurement mode is selected

automatically.
H
Note

2. Center laser beam as described in ‘Laser beam adjustment’ in section 5.9.

3. 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 (red cursor line) to correspond with the
position of the laser and sensor on the shafts.

144

4. Press e to take the first measurement point.

H
After taking measurement point, the clock hour hand moves automatically to the
next clock position. (If the first measured position is 12:00 o’clock, then the hour
hand moves to the 1.30 o’clock position). Note

5. Rotate the shafts to the second measurement position (this could be either
1:30, 3.00, 4.30, 6.00, 7.30, 9.00 or 10.30 o’clock position). If particular
measurement positions are to be bypassed (say due to shaft rotation restrictions),
use the navigations keys and move the screen hour hand (red cursor line) to
correspond to the new position of the laser and sensor on the shafts. Press e
to take measurement point.
 Vertical flanged machines

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.
H Note

7.5 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.
145

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
H Note

Cycle through the coupling results and the flange correction positions using either
w, f or g.
 OPTALIGN smart RS5 handbook

In this example, the sad face

smiley indicates that the
flange needs to be adjusted
in the 0-6 direction.

The shimming correction

value (1.33 mm) and
146 the corresponding bolt
(position 1) 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 i/h to cycle through the shim values.
 Vertical flanged machines

The shimming mode to be applied is set using the “Flange corrections” screen context
menu item ‘Change correction format’. The currently applied shimming mode appears
on the header of the “Flange corrections screen.

current shimming mode (+)

The following options are available:

 Bolt correction (+) – means all shimming corrections are positive (add shims)
 Bolt correction (-) – means all shimming corrections are negative (remove shims)
 Bolt correction (+) – means all shimming corrections are minimized (optimized).
Therefore half of the corrections will be negative and half of them positive. This
option results in zero axial movement of the shaft.
To cycle through the three available shimming modes, press q while in the “Flange
corrections” screen, then highlight the context menu item ‘Change correction format’
and confirm selection by pressing e. The shimming mode changes from (+) to (-)
then to (+).
“Flange corrections” screen may also be accessed via “Results” or “Feet results” 147

screens context menu item ‘Flange corrections’. Press q while in either screen then
use g/f to highlight the context menu item ‘Flange corrections’.
 OPTALIGN smart RS5 handbook

Confirm selection by pressing e. The shim corrections screen appears.

7.6 Machine alignment

Alignment is carried out by correcting angularity and offset.

7.6.1 Correcting angularity

1. Loosen the flange bolts and lift the upper machine.

The machine bolts must be undamaged and removable.

2. Angularity corrections are made by shimming. The shim correction screen shows
a
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, LAMIBLOC or MYLAR.

3. Retighten the bolts and then remeasure to verify shimming results and determine
HNote

the exact alignment condition.

7.6.2 Correcting offset

The correction of offset misalignment is carried out using the Live Move function.
1. Access Live Move by pressing q while in “Results” screen. Use g/f to
highlight the context menu item ‘Move’.

148

2. Confirm selection by pressing e.

3. On confirmation the screen used to position the sensor and laser for the required
move appears. Select the most convenient position.
 Vertical flanged machines

If for any given reason

one would like to initially
perform Live Move in a
different view as presently
displayed, the “Move”
screen context menu item
‘Change view’ is used to
select the required view.

4. 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, 10:30 and 12:00.

It is recommended whenever practical to choose a position where the sensor is

oriented along the same axis as one wishes to move the machine, so that the
move will be tracked along the sensor’s Y-axis.
H Note

5. Use i to position the sensor on the screen to correspond to the position of the
sensor and laser on the shafts.
6. 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.
H Note

7. Loosen the flange bolts. Move the machine laterally in the direction of the bold 149
yellow arrow as indicated in the Live Move display.

8. 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 OPTALIGN smart RS
computer LEDs change from red to amber to green and to blue.
 OPTALIGN smart RS5 handbook

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
H
Note

to check if the new alignment condition is within tolerance.

The orientation of the Live Move may be changed via the context menu of the
“Move” screen.

150
 Configuration

Chapter 8: Configuration and data management

8.1 Shortcut numbers

OPTALIGN smart RS computer 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 numerical data
entry key.
H
Note

8.2 Configuration

The menu item ‘Configuration’ is used to configure the OPTALIGN smart RS computer
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.

151

With expanded menu displayed, use f/g to highlight the context menu item
‘Configuration’, then press e to confirm selection. The “Configuration” screen
displaying items that can be configured appears.
 OPTALIGN smart RS5 handbook

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).

8.2.1 Device settings

The “Device settings” screen is opened by highlighting the ‘Device settings’ icon using
the navigation keys then confirming selection by pressing e. Alternatively, press
1 to directly access the “Device settings” screen. The available settings include
brightness, keyboard beep, power scheme, battery level, resume policy and Bluetooth.
Use f/g to select item to be set.

152

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.

153

The power scheme option is used to select setting that manages the power usage
within the OPTALIGN smart RS 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 selection
confirmed by pressing e.
 OPTALIGN smart RS5 handbook

The capacity of the battery appears next to the battery level bar.

154 ‘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.
 Configuration

The item ‘Bluetooth’ is used to enable or disenable the Bluetooth capabilities of the
OPTALIGN smart RS computer. To turn Bluetooth capabilities on/off, press e with
the item highlighted. The on/off box appears. Use f/g to select either ‘on’ (to
enable Bluetooth capabilities) or ‘off’ (to disenable Bluetooth capabilities), then press
e to confirm selection.

8.2.2 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 highlighting the ‘Regional settings’
icon using the navigation keys then confirm selection by pressing e. Alternatively,
press 2 while in “Configuration” screen to directly access the available settings.

155

Highlighting ‘Units’ using f/g then 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.
 OPTALIGN smart RS5 handbook

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

156

Use h/i to highlight either date, month or year.

 Configuration

Set the date using the data entry keys then confirm entry using either ß or e.
Alternatively, both date and time can be set using f/g.

157
The format in which the date or time is displayed is set via the item ‘Date/time format’.
Use f/g to highlight the menu item ‘Date/time format’.
 OPTALIGN smart RS5 handbook

Pressing e with ‘Date/time format’ highlighted reveals a menu box with the items
‘Date format’ and ‘Time format’. Usef/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.

158
 Configuration

8.2.3 Default settings

The “Default settings” screen is opened by highlighting the ‘Default settings’ icon use
the navigation keys then pressing e to confirm selection. Alternatively, pressing 3
while in the configuration screen to directly 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.

 ‘Default RPM’ – used to set the required default rpm. Use f/g and
highlight ‘Default RPM’ then use the data entry keys to enter the required
default rpm. Confirm entry by pressing either e or ß. Every new alignment
file created will then automatically be preconfigured with this RPM value already
entered.
 ‘Reference diameter’ – used to set the required reference diameter. Use
f/g and highlight ‘Ref. diameter’ then use the data entry keys to enter
the required reference diameter. Confirm entry by pressing either e or ß. 159

Every new alignment file created will then automatically be configured with this
coupling diameter value already entered.
 ‘Default sensor’ – The system’s default sensor is the RS5 sensor. If necessary, the
setting may be used to set the default sensor to either ROTALIGN or OPTALIGN
sensor.
 OPTALIGN smart RS5 handbook

Use f/g and

highlight ‘Default sensor’,
and then press e. The
default sensor options
appear. Use f/g
and highlight required
default sensor, and the
confim selection by pressing
e.

 ‘Workflow assistant’ – used to determine the guidance steps required to carry

out an alignment job. The three options available are: ‘On’, ‘Sensor-coupling
distance auto calculation’ and ‘Off’.

160

 Default mode – used to set the default measurement mode. Three measurement
modes are available – Sweep, Multipoint and Static modes.
 Configuration

 ‘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

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 )

8.2.4 Licence manager

This option is used to licence all possible OPTALIGN smart RS5 applications. The
“Licence manager” screen is opened by highlighting the ‘Licence manager’ icon using
the navigation keys then confirming selection by pressing e.

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.
161

Use the data entry keys to enter the application licence code. Press e to activate
the application.
 OPTALIGN smart RS5 handbook

In most cases, OPTALIGN smart RS5 is delivered with Shaft Alignment application
licenced for the default features level.
The following features are available in the default features level:
 Continuous Sweep measurement mode
 Static measurement mode
 Dynamic tolerance table
 Customer-defined tolerances
 Saving up to 500 measurement files
 Extend detector area
 Ability to print reports directly from the OPTALIGN smart RS computer
 PDF report
 Soft foot measurement
 Ability to define static feet
 Results table to verify measurement repeatability
 Checking pipe strain
 Multiple feet machine correction (six feet machines)
 Averaging
 Vertical machine alignment
 Dial gauge input
 Targets
 Supporting both ROTALIGN and RS5 sensors

To find out which features are available on your particular instrument, press q while
in the “Licence manager” screen.

The menu item ‘About’

162 (described later within this
section) provides a quick
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.

 Configuration

Use f/g to scroll

through the features list.

Missing features may be ordered from PRÜFTECHNIK Alignment Systems. Please

contact your local representative for ordering details.
 All missing optional features may be acquired in one go by ordering part
H
Note

number ALI 12.710 [All Additional Features].

To register any feature, press q while in the “Licence manager” screen, then use
either f or g to highlight ‘Register feature’.

163

Press e to confirm selection.

 OPTALIGN smart RS5 handbook

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. The feature is
now activated and ready
for use.

8.2.5 About application

The information contained under this section is accessed by pressing 3 with the
licence manager context menu open. The displayed information depicts the current
status of the device and application.

164

8.2.6 Printer configuration

This option is used to set up printers and the printing configuration in OPTALIGN
smart RS computer. The “Printer configuration” screen is opened by highlighting the
‘Printer configuration’ icon using the navigation keys then confirming selection by
pressing e.
 Configuration

The default printer type

is ‘PDF file’. This option is
used to save measurement
reports as a PDF file directly
to an approved USB
memory stick.

Four printing options can be set using ‘Printer configuration’.

 Type – Selecting ‘Type’ and then pressing e displays a list with all supported
printers.

If a different printer type

has been selected, one
may revert back to the
default printer ‘PDF file’ if
desired, by pressing 0
when the printer options
are displayed. Alternatively,
select desired type using
f/g. 165

 Paper – Used to select the required paper size

 Orientation – Used to set the paper orientation. Select ‘Portrait’ for a vertical
layout and ‘Landscape’ for a horizontal layout.
 Colour mode – Used to set the colour mode in which the measurement report is
to be printed. This can either be in full colour or in grayscale.
 OPTALIGN smart RS5 handbook

8.2.7 Shaft settings

The “Shaft settings” screen is opened by highlighting the ‘Shaft settings’ icon using
the navigation keys then pressing e to confirm selection. Alternatively, press 6
while in the configuration screen to directly access the available settings. The screen is
used to set specific shaft alignment parameters. The settings are effective immediately.

 Spacer format – used to specify how spacer coupling results are displayed. Seven
options are available.
 Short flex format – used to specify how short flex coupling results are displayed.
Two options are available.
 Angle format unit – used to specify whether angularity should be displayed in
degrees or milliradians.
 All-in-one results – used to activate or deactivate the option to display both feet
and coupling results within a single screen
166  User tolerance type – used to allow user tolerances be defined in either
“symmetrical” or “non-symmetrical” form
 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]
 Configuration

8.3 Data management

OPTALIGN smart RS computer 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, and may be accessed from
the “Machine dimensions” screen above. Use the navigation keys and highlight the
context menu item ‘Open file’ then confirming selection by pressing e. The “Open
file” screen opens displaying a list consisting all stored files.

167

Use f/g and highlight file to be opened, and then press e to open the file.
 OPTALIGN smart RS5 handbook

‘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.

168
 Configuration

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 repre-
sentation
 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 then use f/g to highlight the context
menu item ‘Printer configuration’. Confirm selection by pressing e, then
proceed as described in section 8.2.6 ‘Printer configuration’ previously.

169
 OPTALIGN smart RS5 handbook

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170
 Appendix

Appendix

Updating OPTALIGN smart RS5 to a newer firmware version

H
 OPTALIGN smart RS5 firmware updates are carried out using of the
especially approved PRÜFTECHNIK USB memory stick ALI 4.451.
 Check the PRÜFTECHNIK website [www.pruftechnik.com] to obtain the Note
latest version. If in doubt, please contact your local representative or
PRÜFTECHNIK Alignment Systems.
 If the update is acquired via the website, it must be transferred to the
approved memory stick before commencing the update.

Old PRÜFTECHNIK memory sticks must be disposed of in accordance to the direc-

tive on Waste Electrical and Electronic Equipment (WEEE).

Downloading the firmware from the PRÜFTECHNIK website

The file available for download is an .exe file. Download the file to the desired
directory on a PC.

Note: The update .exe

file is referred to as
‘OPTALIGN smart Shaft
Firmware’.
171

Double-click the file to extract it to the approved memory stick. The following screen
with instructions on how to extract the firmware files into the memory stick appears.

Click ‘Browse’ to select the

location of the approved
PRÜFTECHNIK memory
stick, then click ‘Install‘ to
start file extraction.
 OPTALIGN smart RS5 handbook

Carrying out the firmware update

The firmware update is carried out using the memory stick and the ‘short’ USB cable
ALI 12.503. The actual update does not require a PC.
Before starting the update verify that the USB memory stick has the following files
on it.

The displayed files

and folder are viewed
by expanding the
folder ‘optalign‘. The
downloaded version is
indicated by the prefix
v3_xx_yyyy, where 3_xx
represents the firmware
version and yyyy the build
1. Press e to switch OPTALIGN smart RS computer on. Wait for the dimensions
number.
screen to appear, then press q to view the battery capacity.

172

Before proceeding with the update ensure that the indicated nominal capacity
of the battery is greater than 50%. If this is not the case, recharge the battery to
full capacity first (if using the rechargeable battery package), or replace all six AA
H Note

batteries at the same time.

2. Attach the ‘short’ USB cable ALI 12.503 to the OPTALIGN smart RS computer
socket.
3. Insert the approved PRÜFTECHNIK USB memory stick ALI 4.451 into the ‘short’
USB cable.
 Appendix

4. The system beeps and the LEDs flash. A hint indicating the availability of a new
firmware and the need to reboot the OPTALIGN smart RS computer appears.

173

5. When the hint above appears, press and hold down e until the device reboots.
The display goes dark.
6. The update process will start automatically after a little while (as long as 10
seconds). The system beeps and an LED flashes as the process begins.
 OPTALIGN smart RS5 handbook

Do NOT turn off the device or remove the memory stick during the entire update
process, which takes up to 10 minutes. H
Note

7. When the process is completed, the following hint appears on the display.

174

8. Detach the USB cable from the OPTALIGN smart RS computer then press and
hold down e until the device resets.
OPTALIGN smart RS computer is now ready for use with the uploaded firmware
version.
 Appendix

Checking the uploaded firmware version

1. After the opening dimensions screen appears, press q then use the navigation
and highlight ‘More’ -> ‘About’

2. Press e to confirm selection. The application information screen appears.

The application details

include the uploaded
firmware version, the
application build, currently
loaded features among
others.

175
 OPTALIGN smart RS5 handbook

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

coupling gap difference
750 0.13 0.09
per 100 mm or 10”
176 diameter
900 10.0 7.0

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]
 Appendix

Spacer shafts and [RPM] metric [mm] inch [mils]

membrane (disk)
Acceptable Excellent Acceptable Excellent
couplings

OFFSET 600 3.0 1.8

(per 100 mm spacer
750 0.25 0.15
length or per inch of
900 2.0 1.2
spacer length)
1200 1.5 0.9

1500 0.12 0.07

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

177
 OPTALIGN smart RS5 handbook

OPTALIGN smart RS5 technical data

Computer
CPU Intel XScale PXA270 running at 520 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“)
Lithium-Ion rechargeable battery: 7.2 V / 2.4 Ah (optional)
External interface USB host
USB slave
RS232 (serial) for sensor
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%

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 4 7/16” x 2 1/2”]
Weight 865 g [1.9 lb]
CE conformity EC guidelines for electric devices (2004/108 EC) are fulfilled
RS5 sensor
Particulars 5-axis sensor: 2 planes (4 displacement axes and angle)
Environmental protection: IP 67 (submersible, dustproof)
Ambient light protection: yes
178 Operating temperature: -10°C to 60°C [14°F to 140°F
Storage temperature: -20°C to 80°C [-4°F to 176°F]
Dimensions: approx. 105 x 74 x 53 mm [4 9/64” x 2 29/32” x 2 3/32”]
Weight: approx. 220 g [6 19/25 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
 Appendix

RS5 laser
Particulars Type: Semiconductor laser diode
Beam divergence: 0.3 mrad
Environmental protection: IP 67 (submersible, dustproof)
Beam power: < 1 mW
Wavelength (typical) 670 nm (red, visible)
Safety class: Class 2, FDA 21 CFR 1040.10 and 1040.11
Safety precautions: Do not look into laser beam
Power supply: Batteries 2 x 1.5 V IEC LR6 (“AA“)
Operating temperature: 10°C to 50°C [50°F to 122°F]
Storage temperature: -20°C to 80°C [-4°F to 176°F]
Dimensions: approx. 105 x 74 x 47 mm [4 9/64” x 2 29/32” x 1 27/32”]
Weight: approx. 225 g [7 15/16 oz.]
Bluetooth module for
wireless communication
with sensor
Particulars Class 1 connectivity, transmitting power 100 mW
Transmission distance: up to 100 m [328 ft.] direct line of sight
Complies with FCC rules part 15.247
LED indicators: 1 LED for wireless communication,
3 LEDs for battery status
Power supply: Batteries 2 x 1.5 V IEC LR6 (“AA“)
Operating time: 14 hours typical use (based upon an operating cycle of
50% measurement, 50% standby)
Operating temperature: -10°C to 50°C [14°F to 122°F]
Environmental protection IP 65 (dustproof and water spray resistant), shockproof
Dimensions Approx. 81 x 41 x 34 mm [3 1/8” x 1 11/16” x 1 5/16”]
Weight Approx. 133 g [4.7 oz.] including batteries and cable

Carrying case
Particulars Standard: ABS, drop tested 2 m [6 1/2 ft]
Dimensions: approx. 480 x 400 x 195 mm [18 57/64” x 15 47/64” x 7 43/64”]
Weight, including all standard parts: approx. 8.3 kg [18.3 lb.] .

179
 OPTALIGN smart RS5 handbook

Declaration of Conformity

180
 Index

Index
Symbol
3-machine train All-in-one results 122, 145, 166
Angle format unit
ALI 12.723 119
degrees 166
3-machine trains 119
Angle format units
milliradians 166
A
Attachments 15
Adjustment thumbwheels Auto Sweep 70, 166
Averaging 115
yellow 66
ALI 2.118
small chain-type bracket 7
B
ALI 2.905 Battery
lens cleaning cloth 7
disposal 21
ALI 3.588
Battery housing
tape measure 7
ALI 12.600 18
ALI 4.451
Beam adjustment
memory stick 91
crosshair 69
USB memory stick 7 Bluetooth
ALI 12.200 on/off 155
computer 5 Bluetooth module 25, 105, 138
ALI 12.201 ALI 4.621i 6
computer stand 5
mount 38
ALI 12.502-2
scanning 68
PC cable 6
Bluetooth module cable
ALI 12.503
ALI 3.905-0.28 6
USB cable 7
Bracket
ALI 12.600
anchor peg 37
battery housing 5, 19
ALI 12.651-I mounting 37 181
AC power supply / charger 19
AC power supply/charger 18
C
ALI 12.701 Cardan drive machines 119
shaft firmware certificate 7 Cardan drives
ALI 12.713 set-up 134
optional features Cardan shaft bracket lite
targets, thermal growth, dial gauge 46 ALI 2.874 SET iS 129
ALI 13.700 CD Care
ALIGNMENT CENTER CD 8 system 14
Alignment condition 77 Case
Alignment condition LED OPTALIGN smart RS5
computer
ALI 12.805 5, 14
OPTALIGN smart RS 30 CE compliance 9
Alignment condition LEDs 127 Changing orientation 150
All additional features Charger [universal]
optional
OPTALIGN smart
ALI 12.710 163
ALI 12.651-I 8, 19
 OPTALIGN smart RS5 handbook

Compact chain-type bracket 23 Firmware update

Compact magnetic bracket OPTALIGN smart RS5 171
ALI 2.112 24 Flange configuration 139
Computer keyboard 17 Flanged machines 119
Correcting offset Flip function 63
vertical alignment 148 Flip machines 43
Coupling
type 53 H
Coupling position
Handling precautions 14
jumping 124
Coupling target 53
I
D IEC/EN 60825-1 10
Data entry key Infinirange 112, 114
In-house standards 59, 73
numerical 151 Inspection
Data storage 11 due date 14
Default measurement mode 160
Default mode 162 label 12
Default sensor 159 system 11
Default settings 159 IP65
Device settings 152 computer 11
Dial gauge IP67
configuration 61 laser,sensor 11
Dial indicator readings IP classification 9
conversion 61
Display brightness 152 J
Disposal 15
Job preparation 35, 82
WEEE 11
Distance marking 41
Distance sleeve 131 L
Distance sleeves
Labelling 12
black 131 Laser adjustment 127
182
Dust cap Laser batteries 20
opening aperture Laser beam adjustment 65, 99
Laser centered 69
RS5 sensor/laser 22
Laser end 69
Laser holder 130
E Laser off 69
EC conformity 180 Laser OK 69
Editing box 40 Laser safety
Extending measurement range 69, 88, 112 Class 2 20
Extending range Laser-sensor separation
Laser end 112 maximum 36
Extra-thin bracket Lens cleaning cloth
ALI 2.109 SET 24 ALI 2.905 14
Licence code 161, 164
F Licence manager 161
Lithium-ion rechargeable battery
Feature key 164
ALI 12.601
File resume policy 154
Finishing alignment 87 optional 18
 Index

Live Move 83 O
direction 83
Operating handbook
points to observe 88
OPTALIGN smart RS5
M DOC 12.205.en 8
OPTALIGN smart RS5
Machine name
standard package
editing 46
ALI 12.005-RS5 5
Machine train
OPTIONAL icon 2
set-up 119
Machine trains 119 P
Magnetic brackets
transportation 15, 24 PDF file 165
cover plate 24 Pipe strain 104
Magnetic bracket set measurement report 107
ALI 2.761 SETIS 23 Pipe strain wizard 104
Magnetic sliding bracket Pocket guide
OPTALIGN smart RS5
ALI 2.230 23
Maintenance DOC 12.105.en 8
system 14 Power scheme option 153
Marking measurement positions Predefined bolt patterns 141
Printer configuration 92, 164
vertical shafts 138
Printing
Measurement details 76, 114
Measurement mode measurement reports 91
Continuous Sweep 70 Printing options 92, 168
Product catalogue
Multipoint 70, 109
OPTALIGN smart RS5
Static 110
DOC 12.905.en 8
Static measurement 70 PRÜFTECHNIK website 9
Measurement modes 70, 109
Measurement rotational arc 71 Q
Move corrections
Quarter-turn screw 18 183
machine train 126
Quick alignment check 95
Multiple feet 74
Multiple feet calculator 74
Multipoint measurement mode R
ALI 12.715 Rechargeable battery
optional feature 110 OPTALIGN smart
Multipoint measure mode ALI 12.601 8
ALI 12.715 Reference diameter 159
optional feature 135 Reference mark 144
Reference surface 130
Regional settings 155
N
Results
Negative dimensions All-in-one 72, 96
entering 42 sign convention 72
Results resolution 161
Results screen
‘all-in-one’ 31
 OPTALIGN smart RS5 handbook

Results table 75 System language 156

list 75 System units 155
measurement details 76
Resume function 115 T
RPM
Technical data
default 159
RS5 laser OPTALIGN smart RS5 178
ALI 3.910 6 Temperature
RS5 sensor effects, fluctuations 10
ALI 3.900 6, 23 operating range 10
Thermal growth 46
S Thermal growth calculator 49, 50
Tolerance 73
Safety data sheets 14, 15 Tolerances 56
magnetic brackets 24 non-symmetrical 56, 166
Safety symbols 9 suggested 176
Saving
symmetrical 56, 166
as a PDF file 91
user defined 56, 78
measurement file 90
Tolerance table 58, 59, 78, 166
Saving file 167
Train elements 120
Screen header 147
Train orientation 43
Sensor cable
ALI 3.981-2 6, 23
U
Setting date and time 157
Shaft settings 96, 166 Universal adapter/charger
Shimming 82
mounting and dismounting 19
vertical 82 USB cable ‘short’
Shimming correction 146 ALI 12.503 172
Shims
good quality 82
V
PERMABLOC or LAMIBLOC 148
Shortcut numbers 151 Vertical machine
184
Short flex format 166 alignment 138
Smiley 32
Soft foot 97
W
angular 97
WEEE 15
correction 103
electronic waste 171
checking and correcting 98
WEEE Directive 15
parallel 97 Wireless communication
correction 103 establishing 67
Spacer Workflow assistant 160
spool piece 42 www.pruftechnik.com 14, 15
Spacer format 166
Spacer shaft X
ALI 12.718
XY view 69, 84, 99
optional feature 134
XY View 117
Standard deviation 76
Standard machine absolute values 117
generic 45 relative coordinates 118
Storage requirements 14 relative mode 118