charging the battery

Charging the non-removable rechargeable battery is possible only via the rechargeable battery SHAFTALIGN computer ALI 21.210,

To charge the rechargeable battery, connect the SHAFTALIGN adapter/charger ALI 2K 55 1. X to the SHAFTALIGN computer USB port (grey) and to the mains supply.

Before charging, the rechargeable battery should be discharged as much as possible- To charge the battery from 0% to 100% capacity takes approximately 4 hours. , . , . . , . ^

The battery LED indicates the charging status of the battery. The LED flashes green at initialization and during the charging process. A constantly lit green LED denotes that the battery is fully charged.

The charge level of the battery is displayed under the menu item 'Device settings'. With system switched on, pressing selection by pressing , then using the navigation keys to highlight 'Config', Confirm and from the configuration menu use the navigation keys to highlight The

'Device setting'. Confirm selection by pressing device settings are displayed.

SHAFTALIGN charger/ 5'AA'-size(lECLR6}; alkaline-manganese recommended for the standard computer ALI 21-200

Note alternating battery +/- polarity!

adapter ALI 21 651 X

Battery charge level The SHAFTALIGN adapter/ charger ALI 21,551,X is connected to the rechargeable battery SHAFTALIGN computer ALI21,210viathe USB port.

tJSB port (greyt

Transducer ALI 21.100
The transducer contains a laser diode which emits a beam of red light (wavelength 675 nm). The beam is visible at the point it strikes a surface. It is emitted with a diameter of approx 5 mm (3/16"). Also located i nihesame housing 13 a beam detector which measures the exact position of the laser beam as the shafts are rotated. This component is a biaxial, analog, photoelectric semiconductor position detector with 3 resolution of 1 pm. The transducer also contains an electronic inclinometer with resolution better than 1^ for measurement of the shaft rotation angle.

The transducer has two indicator LEDs on its front side, one green for indicating beam adjustment, and the other red when the laser is on. The transducer is powered by the SHAFTALIGN computer via a cable through which measurement data also passes.

The transducer is IP57 protected to resist water spray and dust. The internal optics and electronics are sealed to prevent any possible contamination. The transducer lens, however, must be kept clean. Use the lens cleaning cloth ALI 2.905 or a fine dusting brush such as that normally used to clean other optical devices. Keep the dust cap on when not in use.

Avoid polishing the lens too vigorously to prevent irreparable damage to its anti-reflective coating.

Under no circumstances may the six smaller housing screws be removed, as that would result in loss of calibration and would void all warranty coverage.

The calibration accuracy of the transducer should be checked every two years as indicated by the coloured label located on the back of the receiver housing. Please return the transducer to your authorized PRUFTECHNIK sen/ice centre for calibration checking, - ■ . " . - . , . ■

Do not stare into the beam!



.., -




, ..

Reflector ALI 5.110
The reflector is always mounted on the shaft or solid coupling of the machine to be moved. It reflects the laser beam back into the position detector as the shafts are rotated. The locking lever flips into the horizontal position, facing forward, to hold the reflector in place on the bracket posts. The reflector is adjusted by changing its vertical

center of bracl<et posts Scratch resistant lens Vertical position adjustment thumbwheel s^ ^ 90° roof prism Measure mark = center of posts Locl<ing l<nob Power/data cable Quick release lever . Keep the dust cap on the reflector when it is not in use. indicates transducer is powered and laser is on Green LED: indicates beam adjustment IP 67 housing ^ Housing marl< . The reflector must be kept clean. Avoid vigorous polishing to preserve the anti-reflective coating. Use the lens cleaning cloth ALl 2 905 or a fine dusting brush such as that normally used to clean other optical devices. Red LED.position and its horizontal angle {using the thumb5crews) so that the beam is reflected directly back into the transducer.

Other bracket types are also available. [Note that the brackets themselves cover the full range of diameters.1 IS R Optional coupling bolt hole brackei All 2.] Chains of varying lengths are also available. broclvet set ALI 2 76! SET OptJonai magnatic sliding bracket ALi 2. The chain-type bracket fits onto shafts and couplings ranging from 15 to 500 mm (1/2" to 20") in diameter.000-R are shown in the "SHAFTALIGN packages" section.118 Compact and lightweight.000 and the rechargeable batten/ package ALI 21. It is only the chain lengths that limit.) ALI 2. TTie SHAFTALIGN standard package ALI 21.230 no. Compact chain-iyce bracket '2 Optional rnagneFn. Contact PRUFTECHNIK Alignment Systems or your local representative for details on additional accessories. Mounting instructions are given in 'Horizontal machine alignment' on page 42. this bracket is designed to provide extremely rigid support for the measurement components with a minimum of mounting time and effort.106 SET Optional compact magnetic bracket ALI 2 112 Ootional extra-thin bracket ALI2.t09SET .Mini compact chain-type bracket ALI 2.

The following screen appears. and display specific system details.Configuration and data management Configuration The configuration menu is used to configure the SHAFTALIGN settings. press ^™ to open the "Configuration menu". The iconi displayed depend on wnethei" the respective optional features have been purchased and licenced for the particular device With "Config" highlighted. licence available applications. Use the navigation keys to highlight the 'Configuration' icon. the regional settings. The configuration menu may be accessed at any !:ime and from any screen. With SHAFTALIGN switched on. Any ol the configuration menu items may be highlighted using the navigation keys. default settings. . access "Configuration menu" screen by pressing '•'-■"''. printer.

These include brightness. use the navigation keys to highlight the "Device settings" icon then confirm selection by pressing ^T . Pressing brightness. SHAFT"AtlGN possesses iv. a beeping sound accompanies the pressing of any key . When the keyboard beep is enabled (on). The available settings are displayed. battery level and resume policy Use to select item to be set. The aufo mode uses a light sensor to automatically adjust the display brightness to match the ambient lighting modp jHd 'he n^nua" mode ALitc mode enables adaptive brightness / Two modes are available to regulate display brightness in 5HAFTALIGN. Press ^T to toggle between keyboard beep on/off.O brightness mo-d-^^ -tiie 5L. power scheme.Device settings To open the "Device settings" screen. Use '©^'/-^ / ^ to revert to the manual mode where display brightness is " increases the brightness and ^ decreases display manually controlled. keyboard beep.

The required setting is selected using Dressing The bc-.n SHAFTALIGN. . and "Long life" (the display dims after 3 minutes and shutdown takes place after S minutes). This value corresponds to ihe charge level indicated on the battery icon that appears on the right top corner of the display.The power scheme option is used to select setting that manages the power usage . The three available options are: "Standard" {the display dims after 10 minutes and shuts down after 1 hour). "Full power" (no dimming and no shutdown).!e!y level status on the :"ich. top corner of the display appears in every screen and confirmed by "^ne capacity of the battery appears next to the battery level bar.

As jin dlterna!i'. Press between the two resume options. Select the required system of units using confirm selection.i"ne policies "Resume policy" allows the user to specify the measurement file that opens when SHAFTALIGN is turned on. A ' and confirming selection by pressing T' reveals the available units of measurement. imperial units (Bntish system) and the SI (metric) units. These are imperial units (US system).'S. the preferred country language. to toggle Regional settings This option is used to set the units of measurement. The system may be set to open the last used measurement file ('Always resume') or open a new measurement file ('Resume manually'). current date and time..^-. ! ^ . jse c^n be [tnade of "/^ to icggle ceivveen the twc 'esL. . The screen is opened from the configuration menu.. Use the navigation keys to higiilight the "Regional settings" icon then confirm selection by pressing Highlighting "Units" using J. Press T' to .

Current date and time are set by highlighting the respective option using -.. month or year . and confirming selection by pressing displays a list of the available country languages.A I -.y.he date tormai displayed here is set via the option 'Date.Highlighting "LanyLiage using ^ / .. ? hiii. date and time format should also be changed to match the default language values. Use to reverse date.dependent on format).?. Press to confirm selection. iippears displaying ni3\or world cities within the selected time zone Note that cnanging the time zone automatically alte's the time set. to set the highlighted date component. a hint appears requesting wheiher the units. Use to select action required and confirm by pressing Highlighting "Time zone" using .-ind confirming selection by pressing Note !hat . Select the preferred country language using .'Time formal". Use Use and to navigate through the date (day. Before the country language is set.'._ / ^ and confirming selection by pressing and displays the different time zones The required zone is selected using confirmed by pressing VVhtT] a time zone is initially Highlighted. to advance date .

On pressing the first key. use the data en try keys to set the date With the required date component highlighted. highlighted time component.Alternatively. Use Alternativeiy. On pressing the first key. enter the new date component using the data entry keys. the editing box appears. Enter value then confirm entry using either or Noie tiiat the time format clispiav'^d here is set via the option "Date/Timo format" Use to toggle between hours and minutes. the editing box appears. Enter value then confirm entry using either or . enter the new time component using the data entry keys. Use to advance time andto to set the reverse time. use the data entry keys to set the time. With the required time component highlighted.

confirming 'Date format' and 'Time format'. . Use selection by pressing "^he lime format is used to set either the 12h or 24h notation. The selected notation i. confirmed by pressing Tne date format is used to set dd-mm-yyyy or mm/dd/yyyy format.dressing with 'Date/time format' highlighted reveals a menu box with the items to select either item.

> Auto-flow . Available options are 3 points and 4 points. Use .Defauft settings To open the "Default settingi" screen.'On' and ' and milliradian. Every new alignment file started will then automatically be preconfigured with this coupling diameter value already entered. With "Active clock" highlighted. The screen is used to set specific de'ault %" to toggle between the two options . The options determine the guidance steps required to carry out an alignment job. The measurement steps 'dimensions' . With auto-flow is on. Confirm entry by pressing . ^-_ / .this is the default measurement mode. the intuitive and progresive auto-flow functionality in SHAFTALIGN guides the operator automatically through the 3 easy steps needed to determine the machinery alignment condition.'results' being prompted the *■ key only.'measure' . Highlight "Ref.y " to cycle througl"! the oaiaineters. press to toggle between the two available cardan units for results display . > Cardan units-with "Cardan units" highlighted. > Active clock . Highlight "Default RPM" then use the data entry keys to enter the required default rpm. Even/ new alignment file started will then automatically be preconfigured with this RPM value already entered. use the navigation keys to highlight the "Default setTings" icon whiie in the configuration menu. The default changes are effective upon restart or if a new file is created. Confirm entry by pressing > Reference diameter . Note that a minimum of 3 measurement points are required for results . Default rpm -used to set the required default rpm.used to set the required reference diameter. press to toggle between the number of measurement points required to obtain results. diameter" then use the data entry keys to enter the required reference diameter.. then confirm selection by pressing .

Tolerance values based on these frequencies may be read off the suggested PRUFTECHNIK Alignment tolerance table.used to set the precision in the results table to 2 [normal resolution] or 3 [high resolution] decimal places Licence inanager "his option IS used to licence SHAFTALIGN ail additional features. The features list is displayed. The following default mode features appear in the features list marked "installed": > Active clock measurement mode . . Confirm selection by pressing . > Results resolution . Use to scroll ttirougli the features list.n the tolerance table. Unmarked features are unlicenced and therefore not available to the user until the feature is purchased and licenced. use the navigation keys to highlight the "Licence manager" icon while in the configuration menu screen. ■• Static measurement mode Tolerance evaluation • Saving up to 50 measurement files ' PDF report To find out which additional features are available on your particular instrument. SHAFTALIGN is delivered licenced for the default mode.the available options ace 50 Hz and 60 Hz.* Tolerance table . The mains supply frequency determines the standard rpm values that appear . Licenced features are referenced by the text 'Installed'. Under normal conditions. Missing features may be ordered from PRUFTECHNIK Alignment Systems or by simply contacting your local PRUFTECHNIK sales representative.

to Press to confirm selection.ys to highlight the 'Feature key' and 'Licence code' boxes Enter the received key and code values using the data entry keys The feature is riovv activ.To register any feature. Use scroll to the feature to be registered. Use the navigation k?. access the features list as described previously.^ted and ready for use .

Confirm selection by pressing . "Colour mode" .Used to set the color mode in which the measurement report IS to be printed.Used to select the required paper size "Orientation" . Four printing options can be set using "Printer configuration". This can either be in full color or in grayscale. Select "Portrait" for a vertical layout and "Landscape" for a horizontal layout. The displayed information depicts the current status of the device and application. . About application The information contained under this section is accessed by highlighting the "About" icon while in the configuration menu screen.Selecting "Type" and then pressingdisplays a list with all supported printers.Used to set the paper orientation. "Type" . "Paper" .Printer configuration This option is used to set up printers and the printing configuration in SHAFTALIGN.

The file menu appears. we are referring to the orange highlight rectangle. These are "Open file".Data management SHAFTALIGN possesses an effective file and data manage. To access the file and data management options. Use to highlight any one of the four file and data management options.'nent facility. . "Save file". "Resume" (or "New file") and "Print report". Note that the file menu items "Resume" and "New file" appear depending on the selected file resume policy which is set under the configuration item "Device settings". Use to cycle the CLirsor through the four file menu items Mote By "cursor". "Resume" appears only when 'Resume manually' is the set policy. press highlight the "File" icon then use the navigation keys to Press to confirm selection.

By defaul: ll'e files ^iie I'SEed in order of dare and tirne or creafon. use the data entry keys to enter the new file name in the editing box that appears. the edning box appears with the existing name highlighted. the edning box appears with the existing name highlighted. Confirm saving by pressing . Highlight "Open file" using then press to confirm selection. This listing o^der is not user-editable then pressing to highlight "Yes".This option is used to save the current file.This option is used to load any stored file. The Open file screen appears displaying all the files saved. use data entry keys to edit file name and confirm changes by pressing 'Save file" . use deleted by pressing to confirm deletion. to highlight the file. If the file is new and does not ^r have a name. The file is To rename an existing file. VJhen saving an already existing open the file.■'Open file" . then use the to highlight file to be opened then press to I'Sted in order of dare and time ot creat'on. Confirm Priss to confirm file name. An existing file may be deleted by highlighting it using When a hint screen appears. saving by pressing VJhen saving an already existing file. This listing By defaul: the files aie o^dei" is not user-editable lJ.

This option is used to call up the last file loaded before the instrument was switched off. and is used to create a new measurement file. > Change printer to PDF file .this option is used to save a complete or graphical measurement report as a PDF file. The following report options are available: ! ! )■ > Complete report . Details of how this option works are found within the section 'Saving data and printing' on page 79. "Resume" . i '. > Text report .this option generates reports in text format only > Graphical report . you may be abte to store up to 200 measurement files.reports printed using this option display only graphical representation.This option toggles with "New file" and appears in the file menu when the resume policy set under device settings is 'Resume manually'. . Tlie default entry level allows you to store 50 files.this option prints a complete report that includes machine graphics and measurement results in both numerical and graphical format. "Print" .This option appears in the file menu when the resume policy set under device settings is 'Always resume'.This option is used to print the measurement report or the soft foot measurement report. "New file" .Depending on the functionality options purchased for your system.

Connect the transducer cable to the transducer port (blue) and switch on SHAFTALIGN by pressing and holding down briefly The LEDs light up followed by a beep. Mount brackets. Shortly afterwards. 2. transducer and reflector. The transducer should be mounted on the stationary machine. Enter dimensions Use the data entry keys to directly enter all required dimensions.Getting started Set up 5HAFTALIGN 1 Prepare the machines by making certain tliat they are locked out. tagged out and all necessary safety precautions have been taken. the machine dimensions screen is displayed. 3. Transducer (Laser) Reilector (Prisnii Stationary machine Movable machine SHAFTALIGN computer .

5. Measure The measurement mode that will be described here is active clock. M5 (Optional! Note: For high vibration environments. Externa! reflector clamp Atl 5. Transducer (sensor/laser) to reflector (prism) Transducer (sensor/laser) to center of coupling Coupling diameter (default is 100 mm / 10") RPM Center of coupling to front foot (right machine) Front foot to bacl< foot (right machine) has been entered. With the dust cap on.The editing box and a hint text for tlie dimension to be entered or edited appears Use the data entry keys to enter this dimension then press to confirm entry The rectangular highlight box moves to the next dimension and the corresponding hint text appears. Active clock and static measurement modes are default. 6. . 3. Initially center the laser dot on the reflector dust cap. Dimensions to be entered include: 1. 'laser off' appears on the screen vi/ith the SHAFTALIGN computer alignment condition LED lit red. Other available measurement modes are optional features. 2. the use of tile optional accessor/. external reflector clamp ALI 5. 4. In this mode. The dimension screen can always be accessed by pressing ■— . measurement points are taken at any 3 or 4 of the 8 available sectors. Repeal the procedure until ail required dimensions have been entered. the measurement screen After the last required dimension appears.116 is recommended.

Adjuit bracket if necessary to center beam horizontally onto the reflector. the dot is centered in the target square.^ Avoid looking directly at the laser beam. and me thumbwheel to make vertical adjustments to position the dot at the center of the target square or as near the center as possible. When the LED turns blue. Tighten bracket. After centering the laser dot. rotate shaft to the first measurement position. . Use the yellow knob to make horizontal adjustments of the reflected laser beam.-p-flector dust cap. Measurement can only be taken when the sector in which the shaft has been positioned is highlighted green. Press 'T to take the measurement point. Slide the reflector on the support posts to center beam vertically onto the . When making the above adjustments. When centered. observe the SHAFTALIGN computer alignment condition LED and the dot on the display screen. The sector 1^: then highlighted orange. When the LED turns green. an indication that measurement has been taken in that particular sector. this is an indication that the reflected beam position is OK and measurement can proceed. remove the reflector dust cap.

Rotate shaft to next measurement position and take point. With stationary machine on the viewer's left. which are initiated automatically after the set measurement points have been taken. . Readings from any 3 or 4 {depending on the default setting) of the 8 available positions (taken in any order) are required for results. Offset is positive when the right coupling half is higher or further away from viewer. Results Alignment results with both coupling and feet results are displayed automatically. gap is positive when open at the top or side away from viewer. Coupling (1)and feel (2j results are displayed in both horizontal and vertical planes The foot resulis show the foot positions relative to the stationary machins centeriine Coupling results are given in the form of gap and offset.

The alignment tolerance status can be displayed using the tolerances feature. A happy Smiley {alignment condition LED lights up blue) -values within excellent tolerances An "OK" icon (alignment condition LED lights up green) values in acceptable tolerances A sad Smiley (alignment condition LED lights up amber or red) -values out of tolerance . Negative values indicate that moveable machine is downwards or towards the viewer.ewer.In foot results positive values indicate that right machine is upwards or away from v.

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d.-. 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! a. making proper alignment difficult or impossible. tolerances T^-^ese values can be obtained from the individual machine specifications. if the optional firmware modules for these functionalities ''"d'. c. lasting shaft alignment that allows long-term uninterrupted machine sen/ice. f. turning the shaft o( coupling end where the lefiector is mounted eliminates the effects of coupling backlash. Shaft play and coupling backlash Axial shaft play of up to 3 mm (1/8") has no adverse effect on alignment results (but (lot necessarily for machine operation [). . alignment targets. and then e-tered into the program. flat foundation A solid.ihtened. as readings are taken only when the transducer moves. Preparing for the alignment procedure Before using SHAFTALIGN. Hydraulic or screw-type positioning aids are recommended for horizontal movement. e. Solid. Thermal growth. b. Soft foot Soft foot causes the machine frame distortion every time the anchor bolts are t. Machine mobility if the machine to be moved stands directly on the foundations. it cannot be lowered *or alignment correction. Because of the measuring principle. Rigid couplings Rigid couplings must be loosened before measurement so that they do not distort the alignment condition. It is therefore advisable to start with about 2 mm (50 mils) of shims beneath the feet of both machines. rigid foundation is required to obtain correct.'e been purchased and activated.Horizontal machine alignment ________ 1.

Choose the shortest support posts which will still allow the laser beam to pass over the coupling flange Insert the support posts into the bracket. refer to the diagrams shown on the next page and follow the instructions carefully. Bracket mounting procedure To fit the compact bracket chains. in order to avoid protruding radially beyond the coupling's outer diameter (OD). 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. and the machines may need to be deliberately misaligned to take this into account. or modify the original bracket configuration supplied by PROFTECHNIK Alignment (for example. Check for soft foot Refer to section on soft foot on page 89 3. alignment may easily be performed over large transducer-reflector separations. Measurement separation Since SHAFTALIGN requires no mechanical connections (such as cantiievered dial indicator brackets) to span over the coupling during measurement. do not use support posts longer than those supplied with the bracket).g. and both at the same rotational position. if such sag does not disappear when machines are put into operation. 2. Note that over very large distances the shafts and coupling may sag. a coupling bolt can be removed and the laser beam shot through the bolt hole. 2. if the coupling is large enough. Mount the brackets Mount the brackets on either side of the machine coupling. Refer to the machine manufacturer's specifications. In some cases. Fasten them in place by tightening the hex screws on the sides of the bracket frame. 1. .

but in cramped or special cases. then remove the chain from its anchor peg. other types of brackets may be required. loosen the thumbnut. insert the chain from the inside of the bracket as shown below.3 Place the bracket on the shaft or coupling. Turn the bracket thumbnut to tighten the assembly onto the shaft. 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. since this could loosen its mounting. The compact chain-type brackets cover most situations. Do not push or pull on the bracket to check. . The bracket should now be tight upon the shaft. if the shaft is larger than the bracket width. insert the chain into the frame from the outside. Please contact your PRUFTcCHNIK representative for details. Tj remove the brackets. 6 Clip the loose end of the chain back onto itself. 4 3 Caich the chain loosely on the anchor peg.

^jm and retightening. if the coupling is iarge enough. Beth transducer and reflector should be at the same height.'lake the final adjustments. loosening the brackets slightly if necessary. yet [jsf high enough for the beam to clear the coupling flange. They should also visually -appear to be parallel to each other. In 5ome cases. as low as passible. removed and the laser beam shot through the bolt bole. then rotating ti-. Match the height of the yellovi/ knob approximately to the tip of the arrow Lever . The bottom of the knob .as viewed from normal working position.Mount reflector -J.-vjuld be flush with the arrow marking on the reflector housing L Flip up the quick-release lever on the side of the reflector housing. a coupling bolt can be ^. in order to avoid protruding radially beyond ■Arrow marking the coupling's outer diameter (OD). then slide the reflector onto the right-hand bracket posts. Return the lever to its horizontal position to secure the reflector on the posts.3 centered to allow for maximum adjustment range later on. Mount the reflector on the support posts of the bracket fixed on the shaft of the right machine ^usually moveable machinei . The yellow knob on thefront of the reflector allows you to adjust the horizontal angle j+ the reflected laser beam. Before you mount the reflector make sure that this knob .

The alignment condition LED lights up followed by a beep Shortly afterwards. Connect the transducer Insert the straight-ended plug of the transducer cable ALI 11.5. .501-2 into the blue transducer port. otherwise the pins inside the plug may be damaged. Match the direction arrows on the plug to the white arrow on the blue port to ensure proper plug orientation. 6. White arrow on blue port White arrow on blue port Disconnecting the transducer To disconnect. the machine dimensions screen appears. Switch SHAFTALIGN on and start application Press 'o^' and hold down for a few seconds. grasp the ribbed collar of the transducer plug and carefully pull it out of the computer transducer port.