Optalign Plus Handbook

OPTALIGN® PLUS
Training
participant handbook
December 2002
Order Number ALI 9.565G
OPTALIGN® PLUS Training Viewfoils
Contents
0. There is a better way! ........................................................................................................... 3
A0. Introduction to Shaft alignment .......................................................................... 4
A1. Causes of machine damage ................................................................................................ 4
A2. What is meant by 'alignment'? ........................................................................................... 5
A3. Laser-optical shaft alignment cuts vibration alarms ......................................................... 6
A4. Laser-optical shaft alignment reduces repair incidence ................................................... 7
A5. Misalignment increases coupling load ............................................................................... 8
A6. Consequences of misalignment: machine damage ........................................................... 9
A7. Four alignment parameters .............................................................................................. 10
A8. Alignment methods in comparison .................................................................................. 11
A9. How accurate are dial indicator readings? ...................................................................... 12
B0. OPTALIGN® PLUS .................................................................................................. 13
B1. . The OPTALIGN® PLUS System ........................................................................................... 13
B2. . Principal advantages of OPTALIGN® PLUS ...................................................................... 14
B3. . New features of OPTALIGN® PLUS ................................................................................... 15
B4. . The OPTALIGN® PLUS measurement principle ................................................................ 16
B5. . The OPTALIGN® PLUS transducer ..................................................................................... 17
B6. . OPTALIGN® PLUS laser emission ...................................................................................... 18
B7. . Position detector linearization ......................................................................................... 19
B8. . Offset and angularity from the calculation ellipse ......................................................... 20
B9. . The OPTALIGN® PLUS control unit ................................................................................... 21
B10. Two power supplies for extended operation .................................................................. 22
B11. The OPTALIGN® PLUS LCD display ................................................................................... 23
C0. Alignment procedure .......................................................................................... 24
C1. . Preparation for alignment: machine mobility ................................................................. 24
C2. . Shaft and coupling play .................................................................................................... 25
C3. . Why is OPTALIGN® PLUS unaffected by torsion play? ................................................... 26
C4. . Soft foot ............................................................................................................................. 27
C5. . Soft foot correction with OPTALIGN® PLUS .................................................................... 28
C6. . Vertical correction with PERMABLOC® shims ................................................................. 29
C7. . Mounting OPTALIGN® PLUS ............................................................................................. 30
C8. Laser beam adjustment ....................................................................................................... 31
C9. . Standard alignment procedure ........................................................................................ 32
C10. Machine dimensions .......................................................................................................... 33
C11. Continuous sweep measurement mode .......................................................................... 34
C12. The multipoint measurement mode ................................................................................ 35
C13. Uncoupled shafts ............................................................................................................... 36
C14. Non-rotatable shafts ......................................................................................................... 37
C15. The 0, 3, 6, 9 measurement mode .................................................................................... 38
C16. Are alignment corrections needed? ................................................................................. 39
C17. Vertical alignment corrections .......................................................................................... 40
C18. Horizontal alignment corrections .................................................................................... 41
C19. The MOVE function ........................................................................................................... 42
C20. Horizontal and vertical MOVE .......................................................................................... 43
D0. Special alignment situations .............................................................................. 44
D1. Accessing special functions ................................................................................................ 44
D2. Thermal growth ................................................................................................................. 45
D3. Entering alignment target values ..................................................................................... 46
D4. Alignment of vertical machines ........................................................................................ 47
D5. Vertical machines: measurement procedure ................................................................... 48
D6. Vertical machines: alignment corrections ........................................................................ 49
D7. Storing and loading measurement files ........................................................................... 50
D8. OPTALIGN® PLUS special functions overview ................................................................. 51
D9. Coordinate display /setting in./mm units ........................................................................ 52
D10.Machines with more than four feet ................................................................................. 53
D11.Alignment tolerance tables .............................................................................................. 54
D12.OPTALIGN® PLUS handles any amount of misalignment ............................................... 55
D13.Selecting static machine feet ............................................................................................ 56
D14.Selection of coupling type ................................................................................................ 57
D15.PC support: The OPTALIGN® PLUS Explorer ALI 5.592 SET ............................................. 58
EO. Standard parts & accessories ............................................................................. 59
E1. . The standard OPTALIGN® PLUS package ALI 5.000 ........................................................ 59
E2. . Compact chain-type bracket ALI 2.892set ........................................................................ 60
E3. . Compact magnetic bracket ALI 2.112set .......................................................................... 61
E4. . Magnetic sliding bracket ALI 2.230 .................................................................................. 62
E5. . Magnetic bracket for coupling bolt holes ALI 2.106set ................................................ 63
E6. . Extra-thin bracket ALI 2.109set ....................................................................................... 64
There is a better way!
© Copyright 2002 PRÜFTECHNIK AG Certain products and procedures shown herein are covered by U.S. and foreign patents and/or patent applications
0
0. There is a better way! Notes:
For years, shaft alignment was considered by

most to be a matter for specialists, whose ______________________________
methods varied from fiddling with dial gages
to simply 'eyeballing' the coupling. More ______________________________
often than not, alignment corrections be-
came a matter of experience at best or sheer ______________________________
guesswork at worst - with the result that
alignment was seen as a time-consuming, ______________________________
nerve-wracking task that often yielded ques-
tionable results. ______________________________
However, maintenance professionals the ______________________________

world over have learned that there is a better
way: OPTALIGN®, the world's first and favor- ______________________________
ite laser-optical shaft alignment system, be-
came a runaway success upon its introduc- ______________________________
tion over a decade ago. Why? Users prize its
accuracy, quickness and ease of use, which ______________________________
have robbed the dreaded alignment spectre
OPTALIGN® PLUS Training participant handbook 12/02
of much of its fear and loathing. ______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
3
Causes of machine damage
THERS
O
Coupling
T
damage
MI
EN
Machine
vibration
Seal wear
AL
S
IG N M
Bearing
damage
A1
A0. Introduction to Notes:

Shaft alignment
A1. Causes of machine damage

______________________________
Up to 50% or more of all premature machine
damage may be traced back to faulty align- ______________________________
ment. This high percentage may seem in-
flated to those who consider conventional ______________________________
alignment methods to be 'successful' already.
Admittedly, such methods may well have ______________________________
been sufficient in the past, when there was
no better method available, but in order for ______________________________
companies to remain viable in today's com-
petitive climate, rotating machinery must be ______________________________
driven at increasingly high speeds and placed
under higher loads, while modern designs ______________________________
tend toward lightweight constructions, so
that design reserves are fully utilized today. ______________________________
All these factors combine to render machines
more vulnerable to the consequences of mis- ______________________________
alignment. This is why better alignment

methods must be developed and applied. ______________________________
OPTALIGN® PLUS provides an extremely cost- ______________________________
effective means of securing proper shaft
alignment for a wide range of rotating equip- ______________________________
ment. It not only offers the quickest available
method of getting machines back into opera- ______________________________
tion following repair, but perhaps more im-
portantly, its extremely high accuracy helps ______________________________
prevent machines from breaking down in the
first place, extending their duration of unin- ______________________________
terrupted service.
4
What is meant by 'alignment?'
Rotating axes must be colinear during operation
A2
A2. What is meant by 'alignment'? Notes:
What is alignment? According to the Society

of German Engineers, alignment means 'the ______________________________
geometrically perfect arrangement of all ro-
tating shafts and wheels.' ______________________________
Ideally, at all locations where shafts are ______________________________

joined, i.e. at the coupling, the shafts should
rotate about a perfectly linear axis to mini- ______________________________
mize coupling strain and wear at the bear-
ings. (One exception: gear tooth couplings ______________________________
require a certain degree of misalignment in
order to maintain tooth lubrication.) ______________________________
This means that both shafts must be turned ______________________________

in their normal direction of rotation (usually
indicated by an arrow marking on the fan or ______________________________
pump housing) during measurement in order
to determine the exact position of their re- ______________________________
spective rotation axes. This is superior to e.g.
rotating only one shaft to take dial gage ______________________________

readings from the opposing coupling surface:
such surface readings are always vulnerable ______________________________
to machining and mounting inaccuracies.
______________________________
______________________________
______________________________
______________________________
5
Laser-optical shaft alignment cuts vibration alarms
Vibration alarms/year
700
600
500
Misalignment
400
300
Other
(bearing damage,
200 unbalance,
looseness)
100
0
1987 1991 1995
Source: Shell Petroleum, UK
A3
A3. Laser-optical shaft alignment Notes:

cuts vibration alarms
Perhaps the most conclusive evidence of the ______________________________

benefits offered by laser-optical shaft align-
ment is the resulting reduction in vibration ______________________________
levels during machine operation. This graph
illustrates the decrease in alarm reports gen- ______________________________
erated due to vibration at a Shell Petroleum
refinery in Great Britain following the intro- ______________________________
duction of OPTALIGN® shaft alignment.
______________________________
The graph supports numerous anecdotal re-
ports that laser-optical alignment does in fact ______________________________
result in smoother machine operation.
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
6
Laser-optical shaft alignment reduces repair incidence
110
Pump 100
repairs
90
80
70
60
55
50
Mechanical
seal 45
repairs
40
35
30
25
20
15
1988 1989 1990 1991 1992 1993 1994 1995
Source: Hoechst AG, Gendorf/Germany
A4
A4. Laser-optical shaft alignment Notes:

reduces repair incidence
This foil illustrates a typical case in the chemi-

cal industry where repair rates on pumps and ______________________________
mechanical seals have fallen dramatically
since introduction of laser-optical shaft align- ______________________________
ment techniques. At Gendorf, the Germany
plant of Hoechst AG, the reduction in repairs ______________________________
was seen to develop over a space of about
five years as more and more of the pumps in ______________________________
the plant were repaired, then subsequently
aligned using OPTALIGN®. (The slight rise ______________________________
during 1995 can be attributed to a consider-
able increase in production that year.) ______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
7
Misalignment increases coupling load
Normal view of
coupling as installed
Infrared photos of thermal radiation
Infrared thermograms courtesy of Infraspection Institute®

With OPTALIGN Without OPTALIGN
A5
A5. Misalignment increases Notes:

coupling load
Infrared thermography makes the increase in ______________________________

coupling load due to misalignment readily
apparent: the hotter the machine element, ______________________________
the brighter it appears on the thermogram.
______________________________
The thermograms shown here were taken on
a typical process pump/motor aggregate ______________________________
which was aligned via typical dial indicator
methods (at right), then using OPTALIGN® (at ______________________________
left). Not only can the flexible element of the
Flender Eupex coupling itself be seen to heat ______________________________
up, but the machines themselves also develop
considerably elevated temperatures. ______________________________
This effectively answers the often-raised ______________________________
question, 'Why bother with precision align-
ment when a flexible coupling is installed?' ______________________________
Even though the flexible coupling itself may

well be able to withstand the effects of shaft ______________________________
misalignment, it still places the machines
under additional loading forces, leading to ______________________________
premature wear (or even failure) of bearings
and seals. ______________________________
______________________________
______________________________
______________________________
8
Consequences of misalignment: machine damage
vibration analysis
Excessive vibration
Bearing damage shock pulse reading
Seal wear from shaft bending

Seal ring opens,
dirt, liquid and gas or
process fluid enter the bearing,
gas escapes under pressure
A6
A6. Consequences of misalignment:

machine damage
What happens when alignment is not accu- 'flexible' couplings are installed).
rate enough? Misalignment leads to excessive The shaft itself is placed under increased load
loading of machines. The consequences may due to misalignment, particularly at the bear-
be manifested as machine vibration. Faulty ings, where the misalignment displacement
alignment may be detected qualitatively us- causes the additional load to reciprocate. This
ing vibration analysis: characteristically, el- flexing action can appreciably shorten the
evated readings are commonly found in the operating life of the shaft.
radial and axial frequency spectra at the
rotational frequency and at multiples thereof. Another machine component particularly sus-
Therefore, it is advisable to check the final ceptible to the damage from misalignment is
alignment condition using vibration measure- the shaft seal. The viewfoil illustrates how
ment techniques, among others. even slight misalignment allows contamina-
Abnormal loading of machines also leads to tion to enter the seal, leading to premature
increased loading of bearings and therefore wear. (The cost of seal replacement is typically
to a reduction of their useful life: even 60% of the pump purchase price!)
'flexible' couplings conduct misalignment
forces from the shafts to the bearings. This
increased loading can be measured using the

shock pulse method of bearing monitoring. Notes:
The shock pulse method may thus be used to
indirectly check the alignment condition. ______________________________
Even though the misalignment at the cou-
pling may be within tolerance, the forces ______________________________
transmitted to the bearings as the shaft
rotates will shorten the life of the bearings. ______________________________
Several critical machine components are sub-
jected to damaging forces when misalign- ______________________________
ment occurs. Foremost among these is the
bearing, which must absorb the additional ______________________________
load created by misalignment (even when
______________________________
9
Four alignment parameters
Vertical offset Vertical angularity
Horizontal offset Horizontal angularity
A7
A7. Four alignment parameters Notes:
There are four different possible discrepancies

from the ideal situation of perfectly aligned ______________________________
shafts which may occur independently.
______________________________
The four distinct alignment parameters are
offset and angularity in the horizontal and ______________________________
vertical planes. These usually occur simulta-
neously to varying degrees, and any given ______________________________
alignment condition between two shafts can
be exactly described in terms of a combina- ______________________________
tion of these four parameters.
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
10
Alignment methods in comparison
Straightedge Dial indicator OPTALIGN® PLUS
Method
Operator
The Wizard The Specialist Anyone
Training NOV
required
Years of Weeks 23 A few
experience to months hours
Alignment
resolution
0.4 mil
max. 4 mils 0.04 mil
ON OFF AUX
1/100 mm
1/10 mm 1/1000 mm
A8
A8. Alignment methods

in comparison
The straightedge has been (and continues to ment until they read zero at all measurement
be) used quite often for alignment. However, positions - ignoring bracket sag and a host of
since the resolution of the human eye is other sources of error (see next viewfoil).
limited to 1/10 mm (0.004"), alignment accu-
racy is correspondingly limited. The OPTALIGN® PLUS system affords an addi-
tional tenfold improvement in accuracy, spe-
The corrective values for machine feet are cifically 1/1000 mm or 0.00004". The com-
usually estimated according to the experience puter automatically calculates corrective val-
of the alignment millwright, who must know ues; as a rule, any operator can achieve
the particular machine involved quite well. consistently good alignment in only one at-
The result: repeated trial alignments are nec- tempt, with a minimum of training or experi-
essary until the machine is more or less ence. The step from dial gages to
aligned, and even then, the accuracy of OPTALIGN® PLUS can be compared with the
results usually leaves much to be desired. step from slide rules to electronic pocket
calculators.
Alignment using dial gages represents a con-
siderable advancement over the straightedge, Notes:
as measuring accuracy of 1/100 mm
(0.0004"), or ten times that of straightedges)

may be obtained - provided that the operator ______________________________
has the necessary training, experience and
diligence to mount the hardware and carry ______________________________
out the procedures properly (see also next
viewfoil). In practice, however, alignment ______________________________
with dial indicators ends up being no more
accurate than with straightedges 90% of the ______________________________
time. Calculations tend to be complicated,
and so more often than not, millwrights use ______________________________
the dial readings for trial-and-error adjust-
______________________________
11
How accurate are dial indicator readings?
455 0
5
45
40 10
35 15 35
10
40
Indicator bracket sag
20
15
30 30
25
25 20
Play in
mechanical linkages
Internal friction /
455 5
45
40 10 10
40
35
15
20 30
35
15 hysteresis
30 25 20
25
Tilted dial indicator

Resolution
1/100 mm (0.5 mil)
(rounding loss)
Reading errors:
• ± sign error
• parallax error Axial shaft play
• mirror image readings
A9
A9. How accurate are Play in mechanical linkages: slight amounts

dial indicator readings? may not be noticed, yet produce large errors
in results.
Until the advent of laser-based alignment Tilted dial indicator: the gage may not be
systems, dial indicators proved capable of mounted perpendicular to the measurement
yielding accurate alignment results. However, surface so that part of the displacement
they are susceptible to a number of factors reading is lost.
which can compromise accuracy:
Axial shaft play: can affect face readings
Indicator bracket sag: should always be mea-
taken to measure angularity unless two axi-
sured before actual alignment readings are
ally-mounted gages are used.
taken - no matter how solid the bracket
appears! These considerations increase the effort and
risk of error with dial indicator measure-
Internal friction/hysteresis: sometimes the
ments.
gage must be tapped in order for the indica-
tor needle to settle on its final value (which
may still not be the correct one).
1/100 mm resolution: up to 0.005 mm
rounding error may occur with each reading -
for a total of up to 0.04 mm error in values Notes:
used for result calculations. This may easily be

compounded several times by the time cou-
______________________________
pling or machine foot results are obtained.
Reading errors: simple human errors that ______________________________
occur all too often when dials must be read
under cramped, poorly-lit conditions and se- ______________________________
vere time constraints. These are often com-
pounded by having to read dials upside-down ______________________________
or front-to-back (using a mirror) at the vari-
ous shaft rotation positions required for ______________________________
alignment measurement.
______________________________
12
The OPTALIGN® PLUS System
B1
B0. OPTALIGN® PLUS Notes:
B1. The OPTALIGN® PLUS System

______________________________
The OPTALIGN® PLUS system consists of
______________________________
• The laser transducer
• The reflector ______________________________
• The control unit
• The connecting cable between transducer ______________________________
and control unit
• The compact chain-type brackets ______________________________
All these components are the product of ______________________________

original research, design and manufacturing
directly by PRÜFTECHNIK , thus eliminating ______________________________
any risk of incompatibility among compo-
nents. OPTALIGN® PLUS profits from the ______________________________
company's many years experience in laser-
optical shaft alignment. The system is made ______________________________
to withstand daily use in rough industrial
surroundings. Operation has been made as ______________________________

easy as possible so that anyone can achieve
perfect, repeatable alignment results with a ______________________________
minimum of effort.
______________________________
Ask your PRÜFTECHNIK Alignment distributor
about the intrinsically safe version of ______________________________
OPTALIGN® PLUS as well!
______________________________
______________________________
13
Principal advantages of OPTALIGN® PLUS
OPTALIGN® PLUS gives you the benefits of:

Many years industry-proven Space-saving reflector design
laser alignment technology fits into places too tight for
other laser systems or dial gages
• low weight reduces sag
Robust laser technology Patented Unibeam® principle means

withstands the shop floor only one laser beam to adjust
Continuous sweep in any Handles gross misalignment or

direction - minimum shaft great separations (e.g. spacer shaft)
rotation determines alignment thanks to Infinirange® extendable
measurement range
DIM
Simple 3-key operation: Calibration to local or
M
1. Enter dimensions international standards
2. Rotate shafts
3. Read results!
Reliable universal/magnetic Instructions store in rear

brackets for quick, easy mounting panel for quick reference
Only one cable: IP67 protection:

eliminates tangling resists shock, water drops & dust
B2
B2. Principal advantages

of OPTALIGN® PLUS
OPTALIGN® PLUS offers a number of unique • The patented Unibeam® principle means
advantages over other shaft alignment sys- there is only one laser beam to adjust
tems: • Ultra-compact reflector fits into spaces too
• Many years industry-proven laser align- tight for other laser systems or dial gages;
ment technology: PRÜFTECHNIK has the low weight reduces sag
know-how to provide the features most • Infinirange ® extendable measurement
needed by maintenance professionals. range handles any amount of misalign-
• Robust laser technology withstands the ment or measurement separation (e.g.
shop floor: rugged IP67 housing protect spacer shaft)
the unit from water spray and grime. • Calibration to local or international stan
• Little shaft rotation required to determine dards with CALI-CHEK T
alignment: obtain accurate alignment re- • Short instructions store in rear panel for
sults with as little as 60° shaft rotation in quick reference
any angular position.
• Simple 3-key operation:
Notes:
1. Enter dimensions
2. Rotate shafts
3. Read results! ______________________________
• Reliable universal/magnetic brackets for ______________________________
quick, easy mounting on a wide range of
shaft and coupling diameters. ______________________________
• Only one cable: eliminates tangling; other
systems need two or more cables, which ______________________________
quickly become knotted during use.
______________________________
• The cable can be disconnected and recon-
nected during measurement rotation with- ______________________________
out affecting results.
14
New features of OPTALIGN® PLUS
OPTALIGN® PLUS gives you
Flexible shaft rotation:

Non-volatile data storage
a) Restricted angle and files are reusable
b) Continuous or by segments
Full PC support and two-way
communication available
c) User-defined positions
Interchangeable
transducers
Freedom from
backlash effects
Intelligent power management

for longer battery life
Tolchek® alignment tolerance

indication at a glance with the
'smiley' Automated reporting via direct
printer connection to any
standard office printer
B3
B3. New features

of OPTALIGN® PLUS
OPTALIGN® PLUS offers the following addi- • Automated reporting via direct printer
tional features: connection with no PC required.
• A choice of measurement methods accom-
modates any type of shaft rotation that Notes:
machines may require:
a) Restricted angle ______________________________
b) Continuous or by segments
c) User-defined positions ______________________________
• Freedom from backlash effects: up to 5°
torsion play has no influence on readings. ______________________________
®
• On screen Tolchek alignment tolerance
______________________________
indication at a glance: The 'smiley' symbol
clearly shows 'go/no-go' condition at both
______________________________
coupling and feet correction values.
• Non-volatile data storage retains up to 99 ______________________________
sets of machine dimensions and results
even after shutoff and files are reusable. ______________________________

• Full PC support for advance job setup,
archival and report generation under Win- ______________________________
dows. Two-way communication between
PC and instrument. ______________________________
• Interchangeable transducers (no longer ______________________________
paired with one particular computer) for
mix-and-match convenience ______________________________
• Intelligent power management for longer
battery life; reserve battery power ensures ______________________________
uninterrupted completion of every align-
ment job. ______________________________
15
The OPTALIGN® PLUS measurement principle
B4
B4. The OPTALIGN® PLUS Notes:

measurement principle
The laser beam used to measure alignment ______________________________

originates in the transducer (shown here
mounted on the left side of the coupling). ______________________________
This bright red beam passes over the coupling
flanges, eliminating mechanical linkages and ______________________________
bracket sag, even over great separation dis-
tances. ______________________________
The beam strikes a reflector (shown mounted ______________________________

on the right-hand machine above) which
differentiates between offset and angular ______________________________
misalignment. The reflector directs the beam
back into the transducer, where its lands ______________________________
upon a position detection system. This com-
ponent delivers the actual alignment mea- ______________________________
surements to the computer in terms of beam
coordinates. The transducer also measures ______________________________
and reports the shaft rotation angle associ-

ated with each set of measurements. ______________________________
As the shafts are turned, any misalignment ______________________________

causes the laser beam to move about slightly
relative to the reflector. The control unit uses ______________________________
the exact displacement measurements to cal-
culate the alignment condition between the ______________________________
shafts. And when the dimensions of the
machine measurement setup are known, the ______________________________
control unit can display the shaft misalign-
ment at the coupling and required corrections ______________________________
at the machine feet.
16
The OPTALIGN® PLUS transducer
Beam adjustment LED'S

Laser inactive
IP 67 housing Adjustment OK
End of range
Out of range
Locking
knobs
Out of range
Scratch-resistant lens End
Power/data
cable -1 -1
Linearized area
Detector surface
B5
B5. The OPTALIGN® PLUS transducer Notes:
The OPTALIGN® PLUS transducer contains a ______________________________

laser semiconductor which emits light in the
red range (wavelength 675 nm) and has a ______________________________
power of less than 1 mW, and therefore
satisfying class II laser requirements. Such ______________________________
semiconductor lasers are remarkably compact
in size and robust in construction. The trans- ______________________________
ducer also contains a position detector which
measures the exact position of the laser beam ______________________________
as the shafts are rotated. This detector is a
biaxial, analog, photoelectric semiconductor ______________________________
position detector with a resolution of better
than 1 µm (1/1000mm or 0.04 mils) and an ______________________________
extendable measurement range capable of
handling any amount of misalignment. ______________________________
Futhermore, the transducer contains an elec-
tronic inclinometer with accuracy better than ______________________________
1° for measurement of the shaft rotation
angle.
______________________________
The transducer has two indicator LEDs on its
front side, one green and the other red, to ______________________________
indicate beam adjustment. The transducer is
powered by the control unit via a cable ______________________________
through which measurement data also
passes. ______________________________
Pay special attention to keep the transducer ______________________________
lens clean at all times, as dust and finger-
prints can result in erroneous measurement ______________________________
values! Use the special optics cleaning cloth
supplied with OPTALIGN® PLUS to clean the
lens.
17
OPTALIGN® PLUS laser emission
Randomized pulse interval

prevents vibration interference
Lase
Ene r saf Laser safety Class 2
rgy ety C
lass
2
Tim
e
EEx ib IIC T4
Zone 1
(Optional)
B6
B6. OPTALIGN® PLUS laser emission Notes:
The laser works in randomized pulse opera-

tion (unaffected by ambient vibration), which ______________________________
is indicated by the control LED located on the
front side of the transducer. The only safety ______________________________
precaution to be taken with this Class II laser
device is to avoid looking directly into the ______________________________
laser beam. No other safety measures must
be taken when working with OPTALIGN® ______________________________
PLUS.
______________________________
Laser type GaAlAs semiconductor
Wavelength 675 nm typical ______________________________
Beam diameter 7 mm / 0.28 in.
Divergence < 0.3 mrad ______________________________
Beam power < 1 mW
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
18
Position detector linearization
Highly accurate linearization = highly accurate alignment on first attempt!
'Raw' detector response Linearized response Calibration data

stored in transducer
7 7
6 6
5 5
4 4
1.1 4.2 1.0 4.0
0.8 5.3 1.0 5.0
3 3
0.6 6.0 1.0 6.0
1.5 6.2 2.0 6.0
2 2 3.0 6.0
1 1
1 1
2 2
3 3
4 4
5 5
6 6
7 7
(2.4, 6.3) ------------------------> (3.0, 6.0)
B7
B7. Position detector linearization Notes:
The actual measurement values used to cal-

culate alignment are obtained from the posi- ______________________________
tion detector. This position detector is not
simply ordered from a supply catalog and ______________________________
then installed into the receiver, but must first
be linearized, i.e. the measurement character- ______________________________
istics of each individual detector to be used
must be measured with extremely high accu- ______________________________
racy so that any nonlinearity can be compen-
sated by the sensor's own microcomputer. ______________________________
Over the past decade, PRÜFTECHNIK has de- ______________________________

veloped its own extremely complex lineariza-
tion process of unmatched precision which ______________________________
gives its OPTALIGN® PLUS position detectors a
useable resolution of 1 micron (1/1000 mm) - ______________________________
a good deal more accurate than any other
manufacturer's alignment system. Lineariza- ______________________________
tion measurements are made at a large num-
ber of points on each position detector. The ______________________________

detector response and corrections for the
individual detector are stored in the trans- ______________________________
ducer. (This means that transducers may be
interchanged regardless of the reflector and ______________________________
control unit used.)
______________________________
______________________________
______________________________
19
Offset and angularity from the calculation ellipse
Offset
Y
0°°
Vertical
f(Y0:00 - Y6:0)
9°°
Angularity Horizontal
X f(Y3:00 - Y9:00)
3°°
6°°
Vertical Horizontal
f(X3:00 - X9:00) f(X0:00 - X6:00)
B8
B8. Offset and angularity Notes:

from the calculation ellipse
By marking the locations on this ellipse where

the measurement points would fall when the ______________________________
transducer and reflector are rotated to 12:00,
3:00, 6:00 and 9:00 positions, it is possible to ______________________________
read off four values that describe the align-
ment in terms of offset and angularity in the ______________________________
horizontal and vertical planes. The measure-
ments actually taken, however, normally do ______________________________
not have to correspond to these exact posi-
tions. ______________________________
These values would apply to the plane where ______________________________

the transducer is attached to the shaft, but
simple trigonometry suffices to convert them ______________________________
for any other desired location - such as the
coupling plane(s) or machine feet. ______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
20
The OPTALIGN® PLUS control unit
ON/OFF/AUX Switch
ON OFF AUX
PC/Printer using
RS232 serial
interface
LCD display
Transducer
ON
OF
F AU
X
Transducer should remain

connected
at all times
during operation!
Sliding key cover
B9
B9. The OPTALIGN® PLUS control unit
The OPTALIGN® PLUS control unit clearly dis- Ask your PRÜFTECHNIK representative about
plays all results on its power-saving LCD the control unit stand which supports the
screen, which guides the user through the control unit at a convenient desktop viewing
entire procedure by means of graphic sym- angle and lets you hang the unit from a
bols. The control unit also powers the laser railing, pipework, motor fin etc. at the job
transducer via a single cable, which also site.
passes results to be displayed from the trans-
ducer to the control unit. Please note that the Not0es:
transducer must be left connected at all times
during operation (except for momentary dis-
connection, for example, to undo entangled ______________________________
cable during shaft rotation).
______________________________
The control unit is designed for especially
easy operation. Its robust flat keyboard nor- ______________________________
mally offers only the keys needed for stan-
dard alignment procedures. A sliding cover ______________________________
reveals special-function keys used only under
______________________________
certain less-frequent alignment circum-

stances.
______________________________
The control unit contains an RS232C serial
interface which allows easy data transfer with ______________________________
a PC and convenient printer connection.
______________________________
The power switch and the sockets for trans-
ducer and RS232C connection are located on ______________________________
the top of the control unit. A pocket in the
rear panel contains a handy folding set of ______________________________
short instructions for quick reference at the
job site. ______________________________
21
2 power supplies for extended operation
ON OFF AUX
MAIN AUX
ON OFF AUX
AUX battery
L
E
IN
L
L
E
A
K
L
C
A
A
R
U
D
LLINLE
CALEKA 0V
RA 1 9,
DU 6LR6
4
MAIN battery set
60
N1
M
Ne
May pas
Nicht explojeter
Nicht wiede de au
ins in feu!
raufla fire! non
Feuer
dbar.Not recha
werfe recha rgeab
n! rgeab le.
le.
No
401 Ba
4 1,5 by
LR
V 14
C
AM
2
Ne
May pas
Nicht explojeter
Nicht wiede de au
ins in feu!
raufla fire! non
Feuer
dbar.Not recha
werfe recha rgeab
n! rgeab le.
le.
No
401 Ba
4 1,5 by
LR
V 14
C
AM
2
B10
B10. Two power supplies

for extended operation
The OPTALIGN® PLUS control unit features Remove batteries as soon as they become
two independent power supplies: a set of six depleted or if the computer is not to be used
standard "AA"-size (IEC LR 6) batteries serves for an extended period to avoid any unpleas-
as the main power supply to the computer ant consequences of battery leakage. Used
and transducer, and a 9V battery serves as an batteries should be disposed of in an environ-
auxiliary (reserve) power supply. This reserve mentally-sound manner in accordance with
battery ensures that the alignment job can be applicable regulations!
completed even if the main battery becomes
depleted. Explosive environments:
To power the control unit from the main

battery set, press the ON/OFF rocker switch • Use only alkali-manganese batteries of the
on the top of the control unit to the left. To makes listed below may be used with the
switch over to reserve power during an align- intrinsically safe version.
ment job: The 9V auxilliary battery must be from
1. Save all data as soon as the 'Batt' symbol Varta, Duracell or Panasonic.
appears in the display! The standard 1.5V batteries must be from
2. Rock the switch all the way from 'ON' (left Philips or Duracell.
position) to 'AUX' (right) without stopping Ensure that the computer is removed from
at the center ('OFF') position: if the unit the explosive environment before chang-
powers down completely during ing batteries.
switchover, the key may be pressed
upon startup to resume operation from • DO NOT use lithium batteries or nickel-
where you left off. Do not make a habit of cadmium rechargeable batteries in explo-
relying on this battery to operate the sive environments.
control unit for longer than necessary.
Any type of batteries can be used, including

alkali-manganese or metal hydride cells.
22
The OPTALIGN PLUS LCD display
Measurement status and user guidance Clear display of results

Current Coupling
measurement alignment
coordinates condition
Vertical gap
lies within
tolerance
Display
prompts user
to rotate
shafts
Gap opens
Elapsed
toward
rotation
bottom of
sector
coupling
Alternating
display
B11
B11. The OPTALIGN® PLUS LCD display
The display of the OPTALIGN® PLUS control shafts are rotated, the laser beam coordi-
unit is a power-saving fixed-segment LCD nates normally change in the display, reflect-
design that is programmed to guide the user ing the amount of shaft misalignment
through all steps of the alignment procedure, present.
from initial beam adjustment and machine
dimension entry through actual measure- Alignment results may be viewed by pressing
ment to alignment results expressed at the the key once (for coupling alignment
coupling or at the machine feet. The large condition) or twice (for machine foot correc-
digits in the top portion of the display indi- tions). The results screen shows a coupling
cate numerical results and detector coordi- symbol or a machine foot symbol as a re-
nates for beam adjustment, and they can minder that coupling condition or machine
also spell out short words, for example the foot corrections have been selected for dis-
directive 'turn' to rotate the shafts in the play; special function F 7 4 lets you choose
continuous sweep (default) measurement which result is displayed first. Each time the
mode, as shown in the viewfoil. key is pressed, the display advances from
one parameter to the next. It features a
When is pressed to start measurement, happy-face symbol (if RPM has been entered)
the screen alternately displays 'turn' and the to indicate compliance with alignment toler-
ances (flashing to indicate 'acceptable' toler-
x,y coordinates of the reflected beam. The

measurement screen shows a view of the ances, steady for 'excellent' values). The +/-
machine as seen from the far right end (for sign convention of numerical results is clearly
horizontal machines, with feet as shown in shown by the corresponding coupling symbol
the foil) or from above (for vertical, flange- (gap open at top or bottom) or by up/down
connected machines). In this view, the eight arrows in the machine foot correction display.
large dots surrounding the shaft signify the
angular positions for measurement or, for
vertical machines, the flange bolt positions.
Any position that lies between the 45° steps
of these display markings are 'rounded' to
activate the nearest possible dot in the dis-
play; internal calculations are, of course,
performed using the exact position. As the
23
Preparation for alignment: machine mobility
Machine puller
C1
C0. ALIGNMENT PROCEDURE Notes:
C1. Preparation for alignment:

machine mobility
______________________________
The first preparatory step toward successful
alignment is to ensure that the machine to be ______________________________
aligned may be moved as required: this in-
cludes vertical mobility upwards (using proper ______________________________
lifting equipment, of course) and down-
wards, should the machine require lowering, ______________________________
as is frequently the case. The latter situation
may be accommodated by inserting 2 to 4 ______________________________
mm (0.08" - 0.16") of shims beneath the feet
of both machines upon initial installation (we ______________________________
recommend shimming both machines initially
so that changes in the foundation condition ______________________________
may later be compensated, if need be).
______________________________
Horizontal positioning of machines is best
performed using jack bolts - or a simple ______________________________
'machine puller' tool shown here - or hydrau-

lic equipment, all of which allow fine control ______________________________
of movement in a slow, gentle and continu-
ous manner. Brute-force methods such as ______________________________
sledge hammers not only make exact posi-
tioning more difficult and can damage ma- ______________________________
chines (by causing chatter marks on bear-
ings), but the vibration could displace the ______________________________
OPTALIGN® PLUS system during the MOVE
function and therefore lead to less accurate ______________________________
monitoring of correction positioning.
______________________________
24
Shaft and coupling play
Axial shaft play: Coupling torsion play (up to 5°):

No effect No effect
C2
C2. Shaft and coupling play
OPTALIGN® PLUS takes advantage of the With conventional alignment systems, torsion
same basic measurement principle as that of play should be eliminated if at all possible for
the reverse indicator method in which two the duration of alignment measurement by
radially opposed dial indicators are mounted using mechanical aids such as dummy bolts
on opposite sides of the coupling (refer to or small wedges to fix the coupling halves so
B8). This means that, like radial indicators, that they can no longer rotate against one
OPTALIGN® PLUS is insensitive to axial move- another. OPTALIGN® PLUS, however, remains
ment of the shafts during rotation. unaffected by coupling backlash of up to 5°
Since both methods actually measure radial (see foil C3 for complete details.)
displacement (of the laser beam or indicator
stems) during shaft rotation, even consider- Notes:
able axial movement will have little if any
practical effect on the measured displace- ______________________________
ment.
The actual amount of beam displacement in ______________________________
the position detectors is directly proportional
to radial offset and shaft angularity. ______________________________
When using OPTALIGN® PLUS, the machine ______________________________

shafts are rotated if at all possible during
measurement. During this rotation, the shafts ______________________________
should not rotate relative to each other, but
instead both should rotate synchronously. ______________________________
This is why before proceeding with measure-
ment, the operator should examine the cou- ______________________________
pling halves for torsion play between them. It
should also be noted that torsion play may ______________________________
not show up until the shafts are aligned,
which would lead to confusing readings dur- ______________________________
ing the final alignment check unless this
effect is recognized and compensated. ______________________________
25
Why is OPTALIGN® PLUS unaffected by torsion play?
Measurements are considered

only during synchronous rotation of shafts:
Torsion play
or back lash:
Measurement evaluation: No effect!
shafts turn together (without play)
First 5° of Last 5° of
shaft rotation shaft rotation
C3
C3. Why is OPTALIGN® PLUS Notes:

unaffected by torsion play?
If left unchecked, torsion play (also known as ______________________________

coupling backlash) could cause the trans-
ducer and reflector to rotate by slightly differ- ______________________________
ent amounts during measurement. This dif-
ference would introduce considerable error ______________________________
into alignment results. OPTALIGN® PLUS
eliminates this effect, however, in several ______________________________
ways.
______________________________
1. Through its autocollimating laser optics
system, which is inherently less susceptible ______________________________
to backlash.
2. Through the measurement procedure it- ______________________________
self: each time the shafts are turned
during measurement by disregarding the ______________________________
first and last 5° of rotation. This ensures
that measurements used for alignment ______________________________
calculation are recorded only during syn-
chronous rotation of the transducer and ______________________________

reflector.
3. By rotating the shaft or coupling end ______________________________
where the prism is mounted. Torsion play
is eliminated as readings are taken only ______________________________
when the transducer moves.
______________________________
Results are therefore reliable and repeatable,
and accuracy remains uncompromised. ______________________________
______________________________
26
Soft foot
Parallel Angular
soft foot soft foot
C4
C4. Soft foot Notes:
Just as a wobbly chair or table is no fun, a

'wobbly' machine causes alignment frustra- ______________________________
tion. The machine stands differently each
time it is aligned, and each set of checking ______________________________
measurements indicates that the machine is
still misaligned. When the machine is bolted ______________________________
down, additional strain is placed upon the
housing, which may then become distorted. ______________________________
This condition, known as 'soft foot,' had ______________________________

gone ignored for the most part until recently
because it is so difficult to measure. Measure- ______________________________
ment and correction are quite simple, how-
ever, through use of OPTALIGN® PLUS and its ______________________________
soft foot function.
______________________________
There are two types of soft foot. Parallel soft
foot means that foundation and machine feet ______________________________
are parallel to one another, which allows
correction simply by adding or removing the ______________________________

correct thickness of shims. Angular soft foot
is caused by foundation and machine feet ______________________________
forming an angle with one another, so ordi-
nary shims will not solve the problem (a ______________________________
characteristic trait of angular soft foot). Pos-
sible solutions include dismounting the ma- ______________________________
chine so that the feet may be ground down
suitably, or using tapered shims to fill the ______________________________
angular space between machine feet and
foundation. ______________________________
27
Soft foot correction with OPTALIGN® PLUS
Quick and easy soft foot measurement

before every alignment job
Begin with foot bolt tightened Loosen bolt to measure Correct with shims
C5
C5. Soft foot correction

with OPTALIGN® PLUS
OPTALIGN® PLUS features a handy function site feet, those two feet will show the highest
designed especially for quick and easy mea- (approximately equal) soft foot readings. In
surement of soft foot - which reduces the that case, only one of those feet should be
temptation to skip this crucial step of align- shimmed by an amount equal to the mea-
ment preparation. sured soft foot value. (See the OPTALIGN®
PLUS instruction manual for further informa-
The function is initiated by pressing the tion on advanced soft foot correction.)
key on the control unit. The display shows a
top view of the machines, with one foot Notes:
flashing. Actual measurement starts when
either the CLR or 0 key is pressed; the M
symbol then begins to flash. As the bolt of ______________________________
this machine foot is then loosened, the nu-
merical value displayed tells the exact soft ______________________________
foot amount by which that foot has lifted
(where '----' = 0). Measurement stops and ______________________________
the value remains in the display when the
key is pressed, or alternatively, the key ______________________________
may be pressed to proceed directly to the

next machine foot. The 'happy face' toler- ______________________________
ance symbol appears only when the measure-
ment is stopped using the key - and, of ______________________________
course, soft foot lies within tolerance. The
procedure is repeated for each machine foot ______________________________
in turn.
______________________________
The soft foot values are then compared for all
machine feet to determine the amount and ______________________________
location of shimming. For example, if the
machine is rocking between diagonally oppo- ______________________________
28
Vertical correction with PERMABLOC® shims
AP 60 x 50 x 0,1
R
PERMABLOC
Ø
X
Size X Y Z Ø
A 60 50 15 M12
B 80 70 22 M18
C 100 80 32 M27
D 130 105 44 M36
C6
C6. Vertical correction

with PERMABLOC® shims
Normally, vertical corrections are the first to sizes or as a complete assortment in their
be carried out following measurement (unless own case. Get in touch with your
horizontal corrective values are considerably PRÜFTECHNIK representative for details.
greater than vertical values). Shims to be used
should be available in advance, as the align- Notes:
ment may be slowed down immensely if ______________________________
hunting and cutting of shims is necessary. No
more than three or four shims should be used ______________________________
beneath each machine foot as greater num-
bers of shims may otherwise act as a stack of ______________________________
springs upon which the machine can bounce,
creating additional soft foot problems. Ideally, ______________________________
precut shims such as PERMABLOC® should be
used, since these allow nearly any thickness ______________________________
up to 3.5 mm to be achieved using only three
shims. ______________________________
If single-thickness shims pose inventory prob- ______________________________

lems due to space required and low turnover,
laminated shims such as LAMIBLOC® (not ______________________________
shown) may prove to be more practical: this
unique construction allows the user to peel ______________________________
shims of 1 mm original thickness down to the
required thickness. ______________________________
Plane parallel and burr-free, both PERMA- ______________________________
BLOC® and LAMIBLOC® shims fulfill all re-
quirements for quick, accurate, reliable shim- ______________________________
ming. Both types are available in individual
29
Mounting OPTALIGN® PLUS
A B C D E
F G
C7
C7. Mounting OPTALIGN® PLUS
The OPTALIGN® PLUS brackets are mounted normal working position), so that the
on either side of the machine coupling, with configuration will match that shown in
both at the same angle (normally vertical). the control unit display.
A. Choose the shortest support posts which The reflector slides onto the bracket posts
will still allow the laser beam to pass over and is held in place when the locking lever
the coupling flange. Insert the support on its side is flipped forward.
posts into the bracket. Both transducer and reflector should be at
B. Fasten the posts into place by tightening the same height, as low as possible, yet
the hex screws on the sides of the bracket just high enough for the beam to clear the
frame. coupling flange.
C. Place the bracket on the shaft or coupling, G. Tighten the yellow knobs to lock the
wrap the chain around the shaft and feed transducer onto the posts.
it through the other side of the bracket.
Notes:
D. Catch the chain loosely on the anchor
peg, then turn the bracket thumbscrew to
tighten the assembly onto the shaft. ______________________________
E. Use the clip at the loose end of the chain ______________________________

to secure it.
The bracket should now be tight upon the ______________________________
shaft. Do not push or pull on the bracket
to check, since that would only loosen its ______________________________
mounting.
______________________________
F. Ensure that the yellow knobs on the
transducer are loosened enough to let you
______________________________
slide the housing onto the support posts.
Install the transducer on the shaft of the
______________________________
machine on the left (as viewed from
______________________________
30
Laser beam adjustment
Adjustment
1. Vertical cap
x, y coordinates
of reflected beam
Adjust to (0,0)
Alternating
display
2. Horizontal
Side thumb wheel
Front knob
C8
C8. Laser beam adjustment
Press the key to start the measurement the position detector within the trans-
process. The transducer and reflector must be ducer. Make a final adjustment to bring
adjusted to reflect the laser beam into the the on-screen (x,y) coordinates to approxi-
middle of the transducer housing aperture as mately (0, 0):
follows: x = horizontal adjustment with the front
knob of the reflector.
1. Remove the cap from the transducer. Do
y = vertical adjustment with the side
not look into the laser beam aperture.
thumbwheel.
2. With the reflector cap still in place, adjust Note: the coordinates do not have to be
the beam onto the center of the target: exactly (0, 0), as this will not affect mea-
· To adjust vertically, slide the reflector surement accuracy. However, a well-cen-
and/or transducer up and down along tered beam makes maximum beam
their support posts. Use the thumbwheel deflection range available to measure
on the side of the reflector housing. maximum misalignment over maximum
· To adjust horizontally, loosen one of the separation.
brackets on the shaft and rotate it slightly.
Once zeroed, the transducer and reflector
Retighten.
must not be touched during measurement, as
3. Remove the cap from the reflector so that any slight movement would then be mea-
the beam strikes the reflector and is re- sured as shaft misalignment.
flected back to the transducer. The trans-
Important:
ducer has a red and a green LED to
Make sure that the transducer lens is clean!
indicate the beam adjustment condition. If
Otherwise measurement accuracy may be
only the red LED is blinking or alternates
compromised!
with the green LED, then the reflected
beam is not striking the detector correctly.
Adjust the reflector horizontally with the
knob on its front until both the red and
green transducer LEDs blink together.
4. The OPTALIGN® PLUS display now blinks
between 'Set0' and the (x,y) coordinate of
the reflected laser beam where it strikes
31
Standard alignment procedure
• Take alignment readings with only three keys

ON OFF AUX
• See alignment condition in a matter of minutes
1. Machine dimensions
2. Measurement
3. Results
C9
C9. Standard alignment procedure
1. Set up OPTALIGN® PLUS 4. Results

Prepare the machines for alignment. In Press to toggle between coupling
particular, rigid couplings (e.g. turbines) alignment and feet corrections:
must be loosened so as not to exert any Coupling values: Press to cycle
force on the shafts. through the horizontal/vertical offsets and
Mount the transducer and prism on the gaps. Compare these results with the
coupling with the transducer on the left machine specifications. The on-screen
(stationary) machine. Connect the trans- 'smiley' usually indicates whether the
ducer to the OPTALIGN® PLUS control unit alignment is within tolerance. If realign-
and switch on. ment is required, switch to foot correc-
2. Enter machine dimensions tions.
Press and key in the dimensions or the Foot corrections: Press a second time,
machines to be aligned, pressing to then to cycle through the horizontal/
confirm each entry. vertical foot values. Shim the vertical val-
3. Adjust beam and measure ues. Press to monitor both vertical
Press to switch on laser. Center the and horizontal corrections.
beam onto the reflector dust cap by slid-
ing the prism and rotating the bracket on
Notes:
the shaft. Remove the dust cap. The
screen blinks 'Set0' and the x,y laser ______________________________
coordinate. Set the coordinates to zero by
adjusting the reflector. ______________________________
When zeroed, rotate the shafts a full turn,
or as far as possible—at least 60°. The ______________________________
transducer makes a series of measure-
ments. ______________________________
______________________________
______________________________
32
Machine dimensions
Beam deflector
ALI 5.106
C10
C10. Machine dimensions
The dimensions required to calculate shaft and rotates to direct the beam onto the floor.
alignment vary according to machine and The distance from the transducer to front feet
coupling types. The control unit displays a is determined by adding 50mm to the dis-
diagram of the machines and flashes the tance between the front foot and the mark
corresponding elements to prompt for each where the beam strikes the floor. The control
required dimension in turn. Tape measure unit switches the laser on automatically only
(supplied with unit) readings are perfectly for the duration of this distance measure-
sufficient for determining these dimensions. ment.
1. Transducer to prism 6. Front foot to back foot, right machine

The distance between the markings on the
tops of the transducer and prism 7. Other dimensions, depending on the ma-
chines involved, such as:
2. Coupling center to transducer • Spacer shaft length
From coupling center to the marking on the • Further foot pairs
top of the transducer housing. • Flange details for vertical machines
3. Coupling diameter Notes:

(Measure the circumference of the coupling

and divide by pi (=3.142). Use speial function
F78 to pre-set diameter. ______________________________
4. RPM (revolutions per minute) ______________________________
OPTALIGN® PLUS requires RPM in order to
evaluate alignment condition according to ______________________________
tolerance tables. Use F79 to pre-set RPM.
______________________________
5. Transducer to front foot, right machine
The beam deflector (ALI 5.106, supplied with ______________________________
the OPTALIGN® PLUS package) may be used
for convenient measurement. The beam de- ______________________________
flector snaps onto the front of the transducer
33
Continuous sweep measurement mode
• For coupled shafts

• Rolling element bearings
• 60° shaft rotation required!
Measurements
are registered
continuously,
automatically
Current
measurement
coordinates
Display
prompts user
to rotate
shafts
Elapsed rotation
(internal
inclinometer) Alternating
display
C11
C11. Continuous sweep

measurement mode
Of the three different measurement modes For highest measurement accuracy, the
offered by OPTALIGN® PLUS, the continuous shafts should be rotated as far as possible -
sweep mode is by far the easiest to use and but alignment can be calculated from as little
perhaps the most versatile as well. This is why as 60° of shaft rotation. The continuous
it is used as the standard default setting when sweep mode of OPTALIGN® PLUS is therefore
the system is first switched into measurement ideal for situations where beam obstructions
mode. It is the ideal mode for coupled shafts. or mechanical restrictions severely limit
Once the laser beam has been adjusted, the coupled shaft rotation for measurement.
shafts are turned together for measurement: Notes:
the inclinometer built into the transducer
triggers a series of measurements at each
different angular position; the slower the ______________________________
shafts are rotated, the more numerous and
the closer together these positions will be. ______________________________
When is pressed to start measurement, ______________________________
the screen alternately displays 'turn' and the
x,y coordinate of the reflected beam. The ______________________________
machine is seen end-on as viewed from the
coupling toward the transducer. ______________________________

The transducer automatically makes a series
of measurements during shaft rotation. The ______________________________
extent of measurement rotation detected by
the inclinometer (built into the transducer) is ______________________________
indicated in the display by the highlighted
segments in the end view of the machine. ______________________________
As the shafts are rotated, the laser beam ______________________________

coordinates normally change in the display,
reflecting the amount of shaft misalignment ______________________________
present.
34
The multipoint measurement mode
• Coupled or uncoupled shafts

• For oil film thickness variations in
white/ sleeve metal bearings
• 3 measurement positions or more
• As little as 60° shaft rotation
required
• For shafts which cannot easily be
turned in one sweep
• For limited measurement positions
C12
C12. The multipoint measurement mode Notes:
This mode is suitable for special circum- ______________________________

stances such as:
• when the line of sight between laser ______________________________
transducer and reflector is blocked over
large segments of shaft rotation, ______________________________
• when shaft rotation is severely restricted,
______________________________
• when oil film thickness variations occur in
white metal bearings, or ______________________________
• when more control over the individual
measurement points than with the 'con- ______________________________
tinuous sweep' method is desired - such
as may be the case with turbines. ______________________________
In multipoint mode, individual measurements ______________________________
are made at a series of rotation angles. This
gives you precise control over the measure- ______________________________
ment in terms of both time and rotation
positioning. At least 3 different points are
______________________________
required over a range of as little as 60°.
To activate multipoint mode, press while ______________________________
in measurement screen. The screen displays
'Pt.1' (measurement point #1). The foils ______________________________
shows the fourth measurement point. The
shafts are then turned to any angular position ______________________________
for the next measurement point. When the
key is pressed to confirm the measure- ______________________________
ment, the display highlights the correspond-
ing bolt in its end view of the machine. ______________________________
Using PRÜFTECHNIK Alignment's technical
note # 33, the multipoint mode can be used ______________________________
for measurement of uncoupled shafts.
35
Uncoupled shafts
Use multipoint measurement mode

• 3 measurement positions or more
• As little as 60° shaft rotation required
Measurement
point number
(x,y) coordinate
of reflected beam
C13
C13. Uncoupled shafts
In order to accurately align two machines to

each another, the position of their shafts axes The screen displays 'tStX' (X=0, 1,2,3...),
must be measured while the shafts are ro- then 'Pt. 1' when the first measurement
tated. In the real world, however, some point is recorded, indicated by a high-
machines do not fulfill this requirement as lighted bolt, followed by the x,y coordi-
their shafts cannot be rotated slowly for nates.
measurement. Especially when long separa- 4. Turn the shaft with the prism assembly to
tions between machines are involved, this the next measurement point (at any de-
condition compromises alignment accuracy sired rotation angle), then place the dust
when conventional measurement methods cap on the prism.
are used. 5. Turn the other shaft (with the transducer
Uncoupled shafts can often be difficult to assembly) until the laser beam is centered
rotate exactly together. PRÜFTECHNIK laser on the vertical line of the prism cap target
alignment products, however, let you rotate as shown at right.
the shafts alternately through a series of Maintain this shaft position while remov-
different measurement angles. No levelling ing the dust cap, then pressing to
devices are required: at each position, the take the next alignment reading. Follow-
visible red laser beam clearly shows when ing the 'tStX' display, the screen displays
both shafts are at the same rotation angle. the second measurement point number,
(Here, the patented multipoint algorithm 'Pt.2', then the x,y coordinates.
even allows several degrees of leeway with
6. Repeat steps 4 and 5 until at least 5 points
no noticeable loss of accuracy!) This simple
have been taken during at least 75° of
procedure is outlined separately here for
shaft rotation.
OPTALIGN® PLUS
7. When finished, press the key.
1. Set up the components and enter ma-
chine dimensions. Turn the shafts to the
first measurement position.
2. Press , align the laser as usual.
3. Press to select multipoint mode and
to take the first measurement.
36
Non-rotatable shafts
When one or both shafts cannot be rotated

Use multipoint measurement mode
• At least 3 measurement positions
• As little as 60° shaft rotation required
Stationary
shaft
Rotatable Oil
shaft
Magnetic
sliding bracket
ALI 2.230
C14
C14. Non-rotatable shafts Notes:
Multipoint measurement mode is also used

to measure non-rotatable shafts. The proce- ______________________________
dure is similar to that described under C13
for uncoupled shafts. The same procedure is ______________________________
also detailed in PRÜFTECHNIK Alignment's
technical note # 33. ______________________________
In this case, use is made of the magnetic ______________________________
sliding bracket, ALI 2.230. This bracket fits
onto the (lightly-oiled) coupling flange or ______________________________
shaft end as shown in foil above and simply
slides to any angular positions. Its powerful ______________________________
magnets ensure the mounting stability
needed for accurate measurement. The mag- ______________________________
netic sliding bracket for stationary shafts is
suitable for all shaft diameters over 80 mm ______________________________
(3 1/8").
The steps described in C13 are then followed ______________________________
carefully.
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
37
The static measurement mode
Coupled & uncoupled shafts

Inclinometer Vertically mounted machines
Eight 45° fixed measurement
positions possible
(at least 3 positions required)
Non-rotatable shafts
9
6
C15
C15. The 0, 3, 6, 9 measurement mode Notes:
This mode is best used for ______________________________

■ comparison with dial gauges or with the ______________________________
original OPTALIGN®
■ non-rotatable shafts ______________________________
■ '4-feet' machines that are mounted verti-
cally.
______________________________
This mode can be used for horizontal or ______________________________
vertical machines since the receiver's incli-
nometer readings are not used in calculating ______________________________
alignment results.
In static mode, individual measurements are ______________________________
made in at least three 45° clock positions as
indicated by an external inclinometer or spirit ______________________________
level. The OPTALIGN® PLUS internal electro-
nic inclinometer is NOT active in this mode. ______________________________
Following beam adjustment, the shafts are ______________________________
turned to each 45° measurement position in

sequence. Each measurement is entered by ______________________________
pressing the key(s) corresponding to the posi-
tion (e.g. '0' at 12:00 position, '3' at 3:00, ______________________________
etc.) 45° positions can be entered by press-
ing, for example, '1 . 3 0 '. Once three ______________________________
positions have been measured, the results
key can be pressed to calculate alignment. ______________________________
Any position may be remeasured, or deleted
by pressing the CLR key. ______________________________
______________________________
38
Are alignment corrections needed?
Results screen gives the answer at a glance:
Coupling alignment condition
Alignment
meets tolerance as
indicated by the
'smiley':
no realignment
necessary
Coupling gap
opens downward
C16
C16. Are alignment corrections needed?
Following measurement, OPTALIGN® PLUS • Coupling gap, vertical

answers this question at the press of the • Horizontal offset
key so that alignment corrections can be • Coupling gap, horizontal
carried out only if the actual condition war- The gap width is expressed at the edge of the
rants further attention. coupling diameter entered in the dimensions
The alignment condition is displayed as mea- screen.
sured at the coupling, and the 'smiley' symbol
indicates at a glance whether the measured Notes:
condition meets alignment tolerances:
• Steady smiley: 'excellent' condition ______________________________
• Flashing smiley: 'acceptable' condition
______________________________
• No happy face: 'unacceptable' condition:
alignment corrections must be made! ______________________________
(See next two viewfoils)
______________________________
These tolerance thresholds are determined by
the coupling type and RPM as entered in the
______________________________
dimensions screen. See viewfoil D11 for com-
plete details. ______________________________
The first coupling alignment parameter dis- ______________________________
played is offset in the vertical direction. The
remaining three parameters that define the ______________________________
alignment condition are displayed in se-
quence each time the key is pressed: ______________________________
______________________________
______________________________
39
Vertical alignment corrections
Clearly indicates required shimming corrections
Correction at
machine feet
Foot to be
raised
(insert
shims)
1.31 mm
Front foot
correction
C17
C17. Vertical alignment corrections Notes:
Vertical alignment corrections may be viewed

by pressing the key twice. ______________________________
The machine foot correction display shows ______________________________
the amounts of vertical shimming and hori-
zontal positioning required to bring the ma- ______________________________
chines into the desired alignment position
(including any thermal growth compensation ______________________________
that may have been entered). Each time the
key is pressed, the display advances from ______________________________
one correction to the next in the following
order: ______________________________
1. Front foot shimming
2. Rear foot shimming ______________________________
3. Front foot horizontal positioning
4. Rear foot horizontal positioning ______________________________
Note that this order applies only to the
standard case where the four feet of the ______________________________
right-hand machine are to be adjusted. Oth-
erwise, corrections are given from left to ______________________________

right in the vertical, then in the horizontal.
The respective foot to be adjusted blinks in ______________________________
the display, and the arrow appearing inside
the right-hand machine indicates whether ______________________________
shims must be inserted (pointing upward) or
removed (pointing downward). The large nu- ______________________________
merical display indicates the exact shimming
amount (which is the same for the machine ______________________________
foot pair that blinks in the display). A nega-
tive value indicates shim removal. ______________________________
______________________________
40
Horizontal alignment corrections
Use either the left or right arrow key to cycle between the
vertical results and the horizontal results
C18
C18. Horizontal alignment corrections Notes:
Cycle through the foot corrections by ______________________________

presssing either or . The amount of
foot correction indicated takes into account ______________________________
any thermal growth and coupling target val-
ues that may have been entered. ______________________________
Press or to alternate between the ______________________________
front feet and the back feet. The correction
appearing on the display applies to the blink- ______________________________
ing feet. The bold arrow in the middle of the
machine to be moved indicates the direction ______________________________
in which the blinking feet should be posi-
tioned. ______________________________
The adapted sign convention used for the
right-hand machine prescribes that for posi- ______________________________
tive values, the blinking feet should be moved
away from the viewer. For negative values, ______________________________
the blinking feet are moved towards viewer.
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
41
The MOVE function
Start MOVE and rotate shaft to any 45° position
C19
C19. The MOVE function Notes:
The MOVE function of OPTALIGN® PLUS al- ______________________________

lows you to follow machine corrections in
both horizontal and vertical directions at both ______________________________
front and back feet as they are being carried
out. ______________________________
Note that since lateral positioning is normally ______________________________
performed after shimming corrections have
been made, a new set of alignment readings ______________________________
should be taken first because the machine
has probably shifted somewhat during shim- ______________________________
ming.
Press to begin adjustment monitoring. ______________________________
The position selection screen comes up.
Turn shaft to any 45° position. The 'bolt dot' ______________________________
on the display shows the selected 45° posi-
tion. With the transducer held at this posi- ______________________________
tion, the horizontal selection view comes up.
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
42
Horizontal and vertical MOVE
Select horizontal (H) or vertical (V) selection view
C20
C20. Horizontal and vertical MOVE Notes:
Choose the desired selection view by pressing ______________________________

or . The horizontal selection view is
used when moving the machine laterally. ______________________________
When positioning the machine vertically, use
the vertical selection view. ______________________________
Confirm selection with . 'Set 0' appears ______________________________

on the screen. Readjust the laser beam for
0,0. Press to begin actual position moni- ______________________________
toring. Only now may the machine bolts be
loosened; also take care to avoid touching ______________________________
the transducer or reflector from this point
onward! ______________________________
The values in the display are constantly up- ______________________________
dated to show the direction and remaining
amount to be positioned. In doing so, the ______________________________
display always shows the machine foot fur-
thest out of line. ______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
43
Accessing special functions
Alignment targets
Enter thermal growth
offsets and angularity
Function key
Calls up special functions
such as coupling type
selection, 6-footed machine
setup, date/time setting
Vertical flanged
machines
Alignment program Printer
Directs output
to printer
Save / open file

Stores/recalls up to
99 machine setups Sliding cover
and results Slides down to
expose 6 special
function keys
D1
D0. SPECIAL ALIGNMENT SITUATIONS Notes:
D1. Accessing special functions
Besides the standard alignment functions de- ______________________________

scribed thus far, OPTALIGN® PLUS is also ca-
pable of handling many unusual situations ______________________________
through use of special functions. These func-
tions are called up using six keys located ______________________________
beneath the sliding key cover of the control
unit. ______________________________
Foremost among these is the key, which ______________________________
initiates these less frequently-used functions.
This section of the viewfoil series deals with ______________________________
these special functions.
Next to the key, the alignment target key ______________________________
allows you to specify the desired cou-
pling alignment condition or the expected ______________________________
amounts of thermal growth at the feet of the
machine to be aligned. These values are then ______________________________
automatically incorporated into the machine

foot corrections displayed by the control unit. ______________________________
Further to the left, the key may be ______________________________
pressed to begin alignment of vertical ma-
chines or horizontal flanged machines. ______________________________
The two keys below that are used to
store and to load machine setups and mea- ______________________________
surement results in the control unit memory.
Up to 99 files may be stored. ______________________________
The printer key directs a graphic align-
ment report to the printer connected to the
______________________________
RS232C interface of the control unit.
44
Thermal growth
D2
D2. Thermal growth Notes:
Shaft-coupled machines often operate at

temperatures high enough to cause an ex- ______________________________
pansion of the machine housing known as
thermal growth, which causes relative dis- ______________________________
placement of shafts from their 'cold' station-
ary positions. This in turn results in deteriora- ______________________________
tion of the alignment condition unless proper
compensatory measures are taken. ______________________________
If the direction and extent of growth are ______________________________
known, the machines may be purposely mis-
aligned cold such that they grow into place, ______________________________
resulting in a good alignment condition dur-
ing normal operation. OPTALIGN® PLUS con- ______________________________
tains a special function designed especially to
incorporate such alignment target values. The ______________________________
most readily available target specifications for
cold alignment are generally obtainable from ______________________________
machine manufacturers; these are usually
expressed in terms of dial indicator readings ______________________________

which must be converted into
OPTALIGN® PLUS-compatible offset and gap ______________________________
form before being entered into the alignment
target function. ______________________________
However, if expected thermal growth values
are known for the machine feet, those ______________________________
amounts may be entered directly into the
OPTALIGN® PLUS control unit using the ma- ______________________________
chine foot option of the alignment target
function. ______________________________
______________________________
45
Entering alignment target values
Expected growth
of motor
0.2 mm
0.2 mm
'Cold' position (coupling targets) Expected growth (at machine feet)

- or -
D3
D3. Entering alignment target values Notes:
Alignment targets may be entered into the

OPTALIGN® PLUS control unit via the target
key located beneath the sliding key
cover. Target values may be entered in either
of two formats:
Press the key once to enter the desired
'cold' alignment condition specified as cou-
pling offset and gap (angularity) for the right-
hand machine relative to the left-hand ma-
chine. The following +/- sign conventions
apply:
Vertical: '+' = right machine is higher (for
offset) or coupling gap opens toward the top
(for angularity)
Horizontal: '+' = right machine is further
away (for offset) or coupling gap opens
toward the rear (for angularity)
These directions are clearly indicated by the
coupling depiction and arrows in the display

when values are entered as positive or nega-
tive (using the key).
Press the key twice to enter in sequence
the expected amount of thermal growth at
each of the movable machine feet. The dis-
play clearly indicates the vertical/horizontal
orientation and the respective machine foot
for which the next growth value is to be
entered. Note the sign convention for ex-
pected foot growth: upward growth is en-
tered as a positive value.
46
Alignment of vertical machines
Angularity: Offset:
corrected by flange bolt shimming corrected by lateral positioning
0.13
0.01
D4
D4. Alignment of vertical machines Notes:
Vertical machines are normally aligned by

adjusting the bolt flange that joins their ______________________________
housings, which are shown here such that the
upper machine is to be aligned to the lower ______________________________
one. Shaft angularity is corrected by inserting
the correct combination of shims so as to tilt ______________________________
the entire upper machine into position with
the lower one. Offset correction calls for ______________________________
lateral displacement of the upper machine in
two directions at once as shown. ______________________________
Due to the extensive shimming calculations ______________________________
required and the difficulty of monitoring two
directions of lateral movement simulta- ______________________________
neously, this alignment situation was consid-
ered quite complicated - until the introduc- ______________________________
tion of OPTALIGN®, that is. OPTALIGN® PLUS
not only calculates proper shimming for any ______________________________
number of bolts at any diameter and the
required lateral displacement in two direc- ______________________________

tions, but it even guides the user through the
lateral adjustment. ______________________________
The following viewfoils describe the vertical
machine alignment procedure in its entirety. ______________________________
______________________________
______________________________
______________________________
______________________________
47
Vertical machines: measurement procedure
Dimensions
7 3
6 4
5
Taking measurements
1. Rotate shafts to match shaft and housing markings
2. Enter position in terms of 0, 3, 6, 9
D5
D5. Vertical machines:

measurement procedure
Since the OPTALIGN® PLUS electronic incli- The OPTALIGN® PLUS alignment function for
nometer is unable to detect the rotational vertical machines is started with the key
position of the vertical shaft, it is necessary to located beneath the sliding key cover. The
mark out a series of angular positions before control unit first prompts the user for entry of
measurement. This may be done by number- machine dimensions. Enter the distances
ing either the shaft or the coupling housing. from transducer to reflector and transducer
Use a thick felt-tip pen or similar, mark a to coupling center as usual. Then enter the
reference position on the coupling housing maximum outer diameter of the bolt flange,
next to the shaft and in line with one of the the distance from transducer to bolt flange,
pillars or bolts. Then make an index mark on the coupling diameter and the RPM.
the shaft. Measure the circumference of the
OPTALIGN® PLUS then prompts the user to
shaft and divide by four. Use this distance to
define each bolt on the flange of the machine
make four evenly-spaced marks on the shaft
to be aligned with the following information:
beginning at the shaft index mark. Number
1. Sequential bolt number (e.g. '1' for the
the points counterclockwise as viewed to-
first bolt), numbered clockwise as viewed
ward the transducer, with '0' as the first
toward the transducer
point, followed by 3, 6 and 9. (For circular
2. Bolt position in degrees, measured clock-
coupling housings, it may be easier to divide

wise from the first measurement position
the circumference of the housing, not the
3. Diameter of bolt circle at the above bolt
shaft, by four and mark it with the 0,3,6,9
position (2x distance from bolt to shaft cen-
positions.) If shaft rotation is limited, you may
ter).
also mark the intermediate 45° positions at
These three items are entered for each flange
1:30, 4:30 etc.
bolt in turn.
The transducer mounts on the shaft (or cou-
Press and adjust the reflected laser beam
pling) of the stationary machine and the
onto the position detector as usual. Then use
reflector goes on the machine to be moved.
the position marks on the shaft and housing
Both components MUST be mounted exactly
to take measurements in at least three posi-
in line with the shaft index mark at the '0'
tions using the mode 0,3,6,9 (as viewed
position.
toward the transducer).
48
Vertical machines: alignment corrections
Lateral correction
monitoring ('MOVE')
at flange
7 3
6 4
5 Shimming corrections
1.45
D6
D6. Vertical machines:

alignment corrections
Alignment results for vertical machines are Following shimming, a new round of mea-
obtained by pressing the key. surement readings should be taken to ensure
The first coupling alignment parameter dis- accuracy of lateral corrections (since the ma-
played is the offset along the axis defined by chine probably was shifted slightly during
the 12:00 and 6:00 measurement positions shimming).
as indicated by the corresponding flange bolt The third time the key is pressed, the
symbols illuminated in the displayed end view control unit displays the lateral positioning
of the machine. The arrow inside the right- corrections at flange, first for the 12:00-6:00
hand machine indicates the direction of off- direction (indicated by the corresponding
set along this 12:00 - 6:00 axis. bolts in the machine end view). The right-
Press the key to proceed to the coupling arrow key switches the display to the 3:00 -
gap result in the same orientation. This figure 9:00 correction.
tells the gap at the edge of the coupling These corrections may be monitored during
diameter previously entered. Press a third their execution through use of the MOVE
and fourth time to show the offset, then the function, which then uses this same vertical
gap results in the 3:00 - 9:00 orientation. machine display arrangement to guide the
user into proper alignment position. Housing
When the key is pressed a second time,

the first flange bolt in the machine end view and shaft markings are required to maintain
flashes alternately with the shimming the 45° (1:30) rotation position of transducer
amount required at that bolt. Pressing the and reflector throughout the procedure.
right arrow key advances to the next bolt. In
this manner, the shimming correction for
each flange bolt can be noted in turn. Note
that these values are always calculated to be
positive; this eliminates the unpleasant pros-
pect of being instructed to remove shims that
are not there to start with!
49
Storing and loading measurement files
OPTALIGN® PLUS stores up to 99 measurement sets
Store results for later comparison, evaluation or transfer to a PC
ON OFF AUX
99
3
1 2
Resume
0 Most recent
measurement
set = no. 0
(inaccessible by PC)
Set up alignment jobs
in advance on a PC with
OPTALIGN® PLUS Explorer
Load with
at startup
D7
D7. Storing and loading

measurement files
OPTALIGN® PLUS contains a non-volatile elec-

To save a file, press and then . To load
tronic memory for storage of up to 99 sets of
a saved file onto OPTALIGN® PLUS, press
measurements and results, even when the
and then enter the file number and then
unit is switched off. This memory allows
press .
convenient comparison with past results and
acts as an alignment data collector for trans- Note that the entire memory can be cleared
fer to a PC for storage and analysis with the by pressing the keys , and .
OPTALIGN® PLUS Explorer program. By the
same token, alignment jobs may be set up Notes:
conveniently in advance on the PC, then
transferred to the OPTALIGN® PLUS memory ______________________________
for recall at the job site.
An additional memory position 0 is reserved ______________________________
for the most recent set of measurements,
which may be called up by pressing when ______________________________
the control unit is first switched on. Since this
'no. 0' position is protected from being over- ______________________________
written by a PC, the most recent measure-

ment set is always secure. ______________________________
The electronic memory is split into two ______________________________
blocks, the main block and the backup. When
the main block is nearly full, the computer ______________________________
pauses to copy all data into the backup block.
The main block is then cleared and ready to ______________________________
use again. This transfer is indicated by a
special sequence of screens and can take up ______________________________
to 40 seconds. However, it will never occur
during a measurement. ______________________________
______________________________
50
OPTALIGN® PLUS special functions overview
+ +
PC Communication Set time and date
Print ASCII list of special function numbers Select report language

Set number of readings for
Print ASCII list of available languages measurement point averaging
Display position detector coordinates Set deviation band
Select units (mm/inch) Set result resolution
Call up intermediate foot corrections Delete all stored measurements
Display time and date Display test (all segments)
Extend measurement range Display test (segments in sequence)
Select stationary machine feet Keyboard test

Hardware/software version
Select report format numbers; transducer ID number
Select coupling type Memory test
Select default result display Reset to original default values
Select default coupling diameter Create a new machine
Select default RPM for tolerances

D8
D8. OPTALIGN® PLUS

special functions overview
The key located beneath the sliding key

cover is used to initiate a wide range of ______________________________
OPTALIGN® PLUS special functions. This foil
gives an overview of all these special func- ______________________________
tions, the most important of which are ex-
plained in detail in the foils that follow. Many ______________________________
of the remaining special functions serve to
adapt the control unit display to specific user ______________________________
requirements (such as metric/inch setting,
time/date setting or various default settings). ______________________________
______________________________
Notes:
______________________________
______________________________ ______________________________
______________________________
______________________________
______________________________ ______________________________
______________________________ ______________________________
______________________________ ______________________________
______________________________ ______________________________
______________________________ ______________________________
______________________________ ______________________________
51
Coordinate display & rotation angle / setting mm/in. units
Display detector coordinates

in 1/1000 mm or 1/10000"
and rotation angle Select display units:
mm or inches
Horizontal
coordinate 1 inch = 25.4 mm
in mm
1 mm = 0.03937 inch
Vertical
coordinate
in mm
Angular
position
in degrees
D9
D9. Coordinate display /

setting in./mm units
OPTALIGN® PLUS contains a special function Notes:

to display the momentary measurement coor-
dinates of the laser beam on the position
detector to the nearest 1/1000 mm or 1/ ______________________________
10000 inch. This function can be used, for
example, as a rough check of radial bearing ______________________________
play when the shaft is lifted.
______________________________
If the detailed coordinate display is required in
inches, first switch to inch mode as directed
______________________________
further below.
The usual measurement screen shows both X ______________________________
and Y coordinates of the position detector at
the same time, scaled from -9 to +9 for ease ______________________________
of beam adjustment. The detailed coordinate
display is activated by pressing the keys , ______________________________
and . The horizontal (x) coordinate of the
detector measurement appears in the nu- ______________________________
merical display accompanied by blinking left/

right arrows to indicate that the horizontal ______________________________
coordinate value is shown. When either the
key or the arrow keys are pressed, the ______________________________
display switches to the vertical coordinate
value, denoted by the up/down arrows that ______________________________
blink in the display and then to the angular
position. ______________________________
At any other time during operation, the
displayed measurement units may be ______________________________
switched between mm and inches by pressing
the key, then . ______________________________
52
Machines with more than four feet
OPTALIGN® PLUS calculates corrections for any desired foot position
200
mm m
7m
0.4
1. Enter desired intermediate location 2. OPTALIGN® PLUS displays required correction
D10
D10. Machines with more than four feet Notes:
When machine with more than four feet (or ______________________________

adjustment points) must be aligned,
OPTALIGN® PLUS contains a special function ______________________________
for display of corrections at intermediate foot
positions. ______________________________
To do so, first enter only the front and rear ______________________________
feet into the dimension screen and measure
the alignment condition as usual. Press the ______________________________
alignment results key twice to enter the
machine foot corrections mode. The arrow ______________________________
keys may be pressed to note shimming at the
front and rear feet. Then enter the new ______________________________
distance from front foot to the intermediate
feet; confirm this entry with the key. Call ______________________________
up the special function for intermediate foot
corrections by pressing the keys and ______________________________
. Intermediate foot corrections can now
be displayed by pressing the arrow keys; the
______________________________
intermediate foot appears as the 'back foot'
of the machine to be moved. ______________________________
This procedure may be repeated as often as ______________________________
necessary for multiple intermediate feet.
Once shimming has been performed, the ______________________________
original front and rear foot positions should
be re-entered if the MOVE function is to be ______________________________
used to follow horizontal position adjustment
in the display. ______________________________
______________________________
53
Alignment tolerance tables
Tolerance [RPM] metric [mm] inch [mils]
OPTALIGN® PLUS
uses 'smiley' symbols to show Soft foot any 0.06 mm 2.0 mils
compliance with tolerances based
Short "flexible" couplings Acceptable Excellent Acceptable Excellent
upon coupling type and RPM.
Offset 600 9.0 5.0

750 0.19 0.09
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 100mm or 10" diameter 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
'Excellent' tolerances fulfilled Spacer shafts and

membrane (disk) couplings
Offset 600 3.0 1.8
'Acceptable' tolerances fulfilled (per 100 mm spacer length 750 0.25 0.15
or per inch spacer length) 1500 0.12 0.07
1800 1.0 0.6
(No happy 'Bad' = Out of tolerance: 3000 0.07 0.04
3600 0.5 0.3
face) Realign!
6000 0.03 0.02
7200 0.3 0.2
D11
D11. Alignment tolerance tables
As mentioned earlier, OPTALIGN® PLUS uses Angularity is usually measured in terms of

the machine RPM from the dimensions screen gap width at the edge of the coupling. For a
to evaluate measured alignment according to given amount of angularity, the larger the
internal tolerance tables. When all four align- diameter, the wider the gap at the coupling
ment parameters are found to lie within edge. The table lists values for coupling
tolerance, a happy face appears in the cou- diameters of 100 mm or 10". You may com-
pling alignment results screen. If the happy pare results directly by entering this coupling
face flashes, alignment fulfills 'acceptable' diameter into OPTALIGN® PLUS, or alterna-
tolerance standards; if the happy face ap- tively, if actual coupling diameter is entered,
pears without flashing, the alignment condi- then multiply the value from the table by the
tion is considered 'excellent'. If no happy face appropriate factor.
appears at all, then alignment is out of For spacer shafts, the table gives the maxi-
tolerance and the machines must be re- mum allowable offset for each 100 mm or
aligned! inch of spacer shaft length.
The suggested alignment tolerances shown "Acceptable" limits are calculated from slid-
in this viewfoil are general values based upon ing velocity of lubricated steel on steel, using
experience and should not be exceeded. They a conservative value of 12 mm/sec. (0.5 in./
are to be used only if existing in-house sec.) for allowable sliding velocity. These val-
standards or the manufacturer of the ma-
ues also coincide with those derived from

chine or coupling prescribe no other values. elastomer shear rates, so they also apply to
Consider all values listed to be the maximum short couplings with flexible elements. The
allowable deviation from the alignment tar- "excellent" values draw on vibration observa-
get, be it zero or some desired value to tions made upon a wide variety of industrial
compensate for thermal growth. In most machines to determine the critical misalign-
cases, a quick glance at the table will tell ment for vibration; however, compliance with
whether coupling misalignment is allowable these tolerance values does not guarantee
or not. Metric tolerances are given for ma- vibration-free operation of a particular ma-
chines with a 50Hz supply running at mul- chine.
tiples/fractions of 3000 RPM. Imperial toler- Since rigid (flanged) couplings have no toler-
ances are given for machines with a 60 Hz ance for misalignment, they should be
supply running at multiples/fractions of 3600 aligned as accurately as possible.
RPM.
54
OPTALIGN® PLUS handles any amount of misalignment
Severe misalignment:
è
Laser leaves detector range during measurement
OPTALIGN® PLUS extends detector range
Range extension procedure:
1. Turn back until coordinates reappear*
2. Press
3. Readjust beam, then press
4. Proceed with measurement
Position detector
D12
D12. OPTALIGN® PLUS handles Notes:

any amount of misalignment
______________________________
In cases of extreme misalignment or vast
separation between transducer and reflector,
______________________________
the laser beam may wander completely out-
side the measurement range of the position
______________________________
detector during shaft rotation or horizontal
adjustment of machine position. In that case,
______________________________
the usual display is interrupted by the mes-
sage 'End' or 'Off', indicating that readjust-
______________________________
ment is necessary before measurement can
be resumed.
______________________________
To do so, first rotate the shafts (or, in the case
of horizontal correction, move the machine) ______________________________
backwards until the usual numerical display
reappears.* ______________________________
Important: maintain this position ______________________________
throughout the following procedure!
______________________________
Then press the keys and to obtain
the beam adjustment display. Readjust the
______________________________
reflector to recenter the laser beam onto the
transducer as usual (indicated by display coor-
______________________________
dinates equal or near to 0 0 ). Press to
confirm satisfactory readjustment, then con-
______________________________
tinue with measurement or correction as
usual. OPTALIGN® PLUS now measures cumu-
______________________________
lative misalignment, i.e. including that previ-
ously displayed. This function may be re-
______________________________
peated several times during the same job, if
necessary.
______________________________
55
Selecting static machine feet
Allows selection of most convenient adjustment points
Static machine feet

(blink in display)
D13
D13. Selecting static machine feet Notes:
OPTALIGN® PLUS allows you to select any two ______________________________

pairs of machine feet (i.e. even those on the
right-hand machine) to remain stationary dur- ______________________________
ing alignment correction. This feature can be
particularly useful when, for example, the ______________________________
machine is 'bolt bound', when attached pip-
ing prevents the right-hand machine from ______________________________
being moved or in order to avoid the prospect
of lowering a machine foot that has no shims ______________________________
in place.
______________________________
Press the keys , and in sequence
to call up this special function, which is then ______________________________
indicated in the display by the letters 'StAt'.
The machine feet currently designated as ______________________________
stationary blink on and off. The and
keys may then be pressed to toggle through ______________________________
all six possible configurations for stationary
machine feet. Press to confirm the cur- ______________________________
rent selection and return to the previous

display. ______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
56
Selection of coupling type
OPTALIGN PLUS allows

selection of result format
Single-plane = 'short' Two-plane = 'long'

(e.g. short flex or rigid couplings) (e.g. spacer shafts)
Results display and tolerance evaluation: Results display and tolerance evaluation:
gap/offset offset B / offset A
B A
D14
D14. Selection of coupling type Notes:
While OPTALIGN® PLUS is preset at the fac-

______________________________
tory to handle short couplings (rigid or flex-
ible), it also contains a special function to
______________________________
allow entry of long (spacer shaft) coupling
dimensions. The measured alignment condi-
______________________________
tion and tolerance indication can then be
displayed separately for each of the two
______________________________
coupling planes.
______________________________
The function is called up using the keys
. The control unit then prompts the
______________________________
user to enter the spacer shaft length.
______________________________
Coupling alignment condition is then ex-
pressed in terms of offset at the two coupling
______________________________
planes, 'Offset A' and 'Offset B', instead of
the gap/offset values displayed for ordinary
______________________________
short couplings.
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
57
PC support: The OPTALIGN® PLUS Explorer ALI 5.592 SET
Data file
transfer and management
ON OFF AUX
Job setup in advance

on the PC Review alignment results
D15
D15. PC support: porated in reports with your favorite text

The OPTALIGN® PLUS processing program. Both the OPTALIGN
Explorer ALI 5.592 SET PLUS Explorer and the OPTALIGN PLUS Editor
The OPTALIGN PLUS Explorer is a Windows- are provided with useful online help.
based PC program. It serves as a platform
that passes all alignment job information Notes:
between OPTALIGN® PLUS and any standard
PC. The transfer of alignment job information
between OPTALIGN® PLUS and the PC is two-
______________________________
way.
______________________________
• The OPTALIGN® PLUS Explorer enables a
suitable hierarchical filing structure. ______________________________
• Using the Explorer, any other document or
web page can be linked to the measure- ______________________________
ment file.
• Linked documents can be accessed using ______________________________
the Explorer
• Measurement files on the Explorer can be ______________________________
attached to e-mails using drag & drop
______________________________
Alignment jobs prepared using the OPTALIGN

PLUS Editor can be transferred onto the
device via the OPTALIGN PLUS Explorer. Mea- ______________________________
surements take on site can also be trans-
ferred on to the PC for analysis and record ______________________________
purposes via the OPTALIGN PLUS Explorer.
This feature not only helps save time but is ______________________________
also in accordance with ISO quality standards.
This has the advantage that a history of ______________________________
machine alignment can be conveniently com-
piled, stored in a format which can be trans- ______________________________
ferred from computer to computer, and incor-
______________________________
58
The standard OPTALIGN® PLUS package ALI 5.000
s
on
cti
tru
Ins
g
tin
era
Op
S
N
IO
T
C
U
R
T
S
IN
T
R
O
H
S
Baby LR 14 C AM2
No 4014 1,5 V
Baby LR 14 C AM2
Baby LR 14 C AM2
au feu! non rechargeable.
No 4014 1,5 V
May explode in fire! Not rechargeable.
No 4014 1,5 V
Nicht ins Feuer werfen!

Nicht wiederaufladbar.
AM2
Baby LR 14 NeCpas jeter
Baby LR 14 C AM2
Ne pas jeter au feu! non rechargeable.

au feu! non rechargeable.
No 4014 1,5 V
No 4014 1,5 V

AM2
Baby LR 14 NeCpas jeter

No 4014 1,5 V


MN1604
DURACELL
DURACELL
6LR61
ALKALINE
9,0V
ALKALINE
E1
E. STANDARD PARTS & ACCESSORIES
E1. The standard

OPTALIGN® PLUS package ALI 5.000 Notes:
The OPTALIGN ® PLUS standard package ______________________________

ALI 5.000 contains the following compo-
nents: ______________________________
OPTALIGN® PLUS control unit ALI 5.200
______________________________
Transducer, incl.dust cap
and connection cable ALI 5.100 ______________________________
Reflector, incl. dust cap ALI 5.110
______________________________
Compact chain-type bracket ALI 2.892set
Short instructions ALI 9.561 ______________________________
Operating instructions ALI 9.560
______________________________
PC cable adapter (25M-9F) ALI 3.265
PC/printer cable ALI 5.221 ______________________________
Serial/parallel converter ALI 5.220 ______________________________

Beam deflector ALI 5.106
______________________________
Tape measure, mm/inch ALI 3.588
Optics cleaning cloth ALI 2.905 ______________________________
OPTALIGN® PLUS case,
(ABS, black) ALI 5.010 ______________________________
Total weight with all ______________________________
standard parts appx. 6.8 kg
Also available: ______________________________
Intrinsically safe package ALI 5.000EX.
59
Compact chain-type bracket ALI 2.892set
Quick & easy mounting

on a wide range of diameters
E2
E2. Compact chain-type bracket Notes:

ALI 2.892set
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 ______________________________
compact chain-type bracket fits onto shafts
and couplings ranging from 15 to 200 mm (1/ ______________________________
2" to 8") in diameter. The support posts are
changeable to suit shaft or coupling diam- ______________________________
eter, and the different sizes are color coded
for quick and easy identification. It is supplied ______________________________
as the standard bracket with
OPTALIGN® PLUS, whose carrying case fea- ______________________________
tures a foam liner with contoured cutouts to
hold all bracket parts securely in place. ______________________________
Should shafts and couplings with diameters ______________________________

greater than 200 mm need to be measured,
then the compact chain-type bracket may be ______________________________
used with a longer tension chain, ALI 2.116.

This chain can measure diameters upto 500 ______________________________
mm.
______________________________
______________________________
______________________________
______________________________
60
Compact magnetic bracket ALI 2.112set
Rigid mounting in a matter of seconds -

for uncoupled shafts as well
E3
E3. Compact magnetic bracket Notes:

ALI 2.112set
Especially when large machines are to be

aligned, the coupling flange may be the most
______________________________
advantageous surface for mounting the
OPTALIGN® PLUS transducer and reflector.
______________________________
This compact bracket uses four powerful rare

______________________________
earth neodymium magnets to hold the stan-
dard OPTALIGN® PLUS support posts against
______________________________
any flat, smooth ferromagnetic surface. This
makes for extremely quick and convenient
______________________________
mounting while maintaining the high accu-
racy achieved with other OPTALIGN® PLUS
______________________________
brackets.
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
61
Magnetic sliding bracket ALI 2.230
Perfect for measuring

non-rotatable shafts
Stationary
shaft
Rotatable
shaft
Oil on shaft end
or coupling
flange
E4
E4. Magnetic sliding bracket Notes:

ALI 2.230
In order to accurately align two machines to

each another, the position of their shafts ______________________________
must be measured by measuring radial dis-
placement (such as OPTALIGN® PLUS does) ______________________________
while the shafts are rotated. Unfortunately,
some machines do not fulfill this requirement ______________________________
as their shafts cannot be rotated slowly for
measurement. Especially when long separa- ______________________________
tions between machines are involved, this
condition compromises alignment accuracy ______________________________
when conventional measurement methods
are used. ______________________________
However, the OPTALIGN® PLUS magnetic slid- ______________________________

ing bracket offers an elegant solution to this
dilemma. The bracket fits onto the coupling ______________________________
flange as shown and simply slides around to
the required measurement positions. A bit of ______________________________
light oil applied to the contact surface will

help the bracket to glide smoothly, avoiding ______________________________
unnecessary vibration which could slightly
change the position of the receiver or emitter ______________________________
on the bracket posts. The powerful magnets
ensure the mounting stability needed for ______________________________
accurate measurement. The magnetic sliding
bracket for stationary shafts is suitable for all ______________________________
shaft diameters over 80 mm (3 1/8").
______________________________
62
Magnetic bracket for coupling bolt holes ALI 2.106set
No radial clearance required:

Laser beam passes through bolt hole
E5
E5. Magnetic bracket for Notes:

coupling bolt holes ALI 2.106set
This magnetic bracket can serve as a useful

substitute for the standard chain-type bracket ______________________________
when the system must be mounted on large
couplings with large bolt holes. Thanks to its ______________________________
four powerful rare earth neodymium mag-
nets, this bracket provides quick and sturdy ______________________________
mounting by straddling the bolt hole. No
radial clearance is required beyond the cou- ______________________________
pling circumference. This space-saving design
can save alignment time when space is tight ______________________________
around the coupling.
______________________________
The basic principle remains the same as when
other OPTALIGN® PLUS brackets are used. ______________________________
However, once the coupling bolt is removed,
this bracket can be placed upon the coupling ______________________________
flanges as shown. The OPTALIGN® PLUS
______________________________
transducer and reflector simply slide onto

their support rods and are fixed into place by
the upper bracket arm. The entire assembly is ______________________________
then positioned on the coupling so that the
laser beam passes directly through the bolt ______________________________
hole.
______________________________
Use only the 115 mm (4½") support rods
supplied with the bracket. The position of the ______________________________
support rods may be changed by loosening
the hex screws which clamp them in the ______________________________
bracket.
63
Extra-thin bracket ALI 2.109set
For mounting in extremely narrow spaces

between coupling flange & machine housing
E6
E6. Extra-thin bracket ALI 2.109set Notes:
In some alignment situations, space along the

shaft or coupling may be so tight that the ______________________________
standard quick-fit brackets may be difficult or
impossible to mount. In such cases, the extra- ______________________________
thin bracket (ALI 2.109) offers the perfect
solution. With a thickness of only 8 mm (5/ ______________________________
16"), it fits into virtually any available gap
between machine housing and coupling, and ______________________________
fits onto any shaft diameter up to 160 mm (6
5/16“). The smaller version, ALI 2.109L set ______________________________
extra-thin bracket fits onto shaft diameters
up to 96 mm (3 3/4“). ______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
64
PRÜFTECHNIK Alignment Systems
Oskar-Messter-Straße 15
D-85737 Ismaning, Germany
www.pruftechnik.com
Tel.: +49 (0)89-99616-0
Fax: +49 (0)89-99616-200
eMail: info@pruftechnik.com Printed in Germany ALI 9.565.01.02.0G
OPTALIGN®, ROTALIGN® and PERMABLOC® are reg-

istered trademarks of PRÜFTECHNIK AG. PRÜF-
TECHNIK products are the subject of patents
granted and pending throughout the world. Con-
tents subject to change without further notice,
particularly in the interest of further technical devel-
opment. Reproduction, in any form whatsoever,
only upon express written consent of PRÜFTECHNIK.
© Copyright 1997 by PRÜFTECHNIK AG
Productive maintenance technology

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OPTALIGN® PLUS

0. There is a better way! Notes:

For years, shaft alignment was considered by

However, maintenance professionals the ______________________________

of much of its fear and loathing. ______________________________

A0. Introduction to Notes:

A1. Causes of machine damage

alignment. This is why better alignment

Rotating axes must be colinear during operation

A2. What is meant by 'alignment'? Notes:

What is alignment? According to the Society

Ideally, at all locations where shafts are ______________________________

This means that both shafts must be turned ______________________________

rotating only one shaft to take dial gage ______________________________

A3. Laser-optical shaft alignment Notes:

Perhaps the most conclusive evidence of the ______________________________

Source: Hoechst AG, Gendorf/Germany

A4. Laser-optical shaft alignment Notes:

This foil illustrates a typical case in the chemi-

Infrared photos of thermal radiation

Infrared thermograms courtesy of Infraspection Institute®

A5. Misalignment increases Notes:

Infrared thermography makes the increase in ______________________________

Even though the flexible coupling itself may

Bearing damage shock pulse reading

Seal wear from shaft bending

A6. Consequences of misalignment:

increased loading can be measured using the

Vertical offset Vertical angularity

Horizontal offset Horizontal angularity

A7. Four alignment parameters Notes:

There are four different possible discrepancies

A8. Alignment methods

(0.0004"), or ten times that of straightedges)

Tilted dial indicator

A9. How accurate are Play in mechanical linkages: slight amounts

used for result calculations. This may easily be

B0. OPTALIGN® PLUS Notes:

B1. The OPTALIGN® PLUS System

All these components are the product of ______________________________

surroundings. Operation has been made as ______________________________

OPTALIGN® PLUS gives you the benefits of:

Robust laser technology Patented Unibeam® principle means

Continuous sweep in any Handles gross misalignment or

Reliable universal/magnetic Instructions store in rear

Only one cable: IP67 protection:

B2. Principal advantages

OPTALIGN® PLUS gives you

Flexible shaft rotation:

Intelligent power management

Tolchek® alignment tolerance

B3. New features

even after shutoff and files are reusable. ______________________________

B4. The OPTALIGN® PLUS Notes:

The laser beam used to measure alignment ______________________________

The beam strikes a reflector (shown mounted ______________________________

and reports the shaft rotation angle associ-

As the shafts are turned, any misalignment ______________________________

Beam adjustment LED'S

B5. The OPTALIGN® PLUS transducer Notes:

The OPTALIGN® PLUS transducer contains a ______________________________

Randomized pulse interval

B6. OPTALIGN® PLUS laser emission Notes:

The laser works in randomized pulse opera-