Date post: | 08-Apr-2018 |
Category: |
Documents |
Upload: | jamie-clarke |
View: | 221 times |
Download: | 0 times |
of 394
8/6/2019 Laser Alignment 97191
1/394
Reference Manual
2130 RBM Consultant Pro
Laser AlignmentAnalyzer and Fixtures
Part # 97191 Rev. 1
8/6/2019 Laser Alignment 97191
2/394
ii
Copyright
2007 by Emerson Process Management.All rights reserved.
No part of this publication may be reproduced, trans-mitted, transcribed, stored in a retrieval system, ortranslated into any language in any form by any meanswithout the written permission of Emerson ProcessManagement.
Disclaimer
This manual is provided for informational purposes.EMERSON PROCESS MANAGEMENT MAKES NO WAR-RANTY OF ANY KIND WITH REGARD TO THIS MATERIAL,INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WAR-RANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-TICULAR PURPOSE. Emerson Process Management shallnot be liable for errors, omissions, or inconsistenciesthat may be contained herein or for incidental or con-sequential damages in connection with the furnishing,performance, or use of this material. Information in this
document is subject to change without notice and doesnot represent a commitment on the part of EmersonProcess Management. The information in this manual isnot all-inclusive and cannot cover all unique situations.
Product Support
Should you have any comments on this documentationor questions concerning the Agreement on the fol-lowing pages, please contact Emerson Process Manage-
ments Product Support Department.Addresses:
The Americas and Canada
Emerson Process Management
835 Innovation Drive
Knoxville, TN 37932 USA
Phone: 865-675-4274
FAX: 865-218-1416
Europe and Middle East
Emerson Process Management
Research Park Inerleuvenlaan 50 Leuven 3001Belgium
Phone: 32/16/74/.14.71
UK 441516779418
FAX: 32/16/74.14.19
Asia Pacific
Emerson Process Management Asia Pacific Pte Ltd
1 Pandan Crescent
Singapore 128461
Phone: 65.67708706
FAX: 65.67708006
Worldwide Web:
http://www.MHM.AssetWeb.com
AMS Machinery Manager Reference Manual
This document was written, illustrated, and producedby Emerson Process Managements Engineering Publi-cations Group on Power Macintosh workstationsusing Adobe FrameMaker, Adobe PhotoShop, andMacromedia FreeHand. Printed copies are producedusing the Xerox DocuTech publishing system.
Trademarks and Servicemarks
Emerson Process Management logo; Infranalysis; Infra-Route; MachineView; MotorView; Nspectr; OilView(Japan); AMS Machinery Manager; Reliability-BasedMaintenance, and logo; are registered trademarks of
Emerson Process Management.PeakVue; RBMview; AMS Machinery Manager (Aus-tralia, China, Japan); RBMwizard; Reliability-BasedMaintenance (Venezuela); SonicScan; SST; VibPro; andVibView are pending trademarks of Emerson ProcessManagement.
Lubricant Profile and Trivector are registered service-marks of Emerson Process Management.
RBM; AMS Machinery Manager (China); Reliability-Based Maintenance (Venezuela); and design arepending servicemarks of Emerson Process Manage-ment.
Adobe is a trademark and FrameMaker and PhotoShopare registered trademarks of Adobe Systems, Inc. PowerMacintosh is a trademark of Apple Computer, Inc. Mac-romedia is a registered trademark and FreeHand is a
trademark of Macromedia, Inc. Xerox and DocuTechare trademarks of Xerox Corporation.
8/6/2019 Laser Alignment 97191
3/394
iii
All other brand or product names are trademarks or reg-istered trademarks of their respective companies.
Patents
The product(s) described in this manual are coveredunder existing and pending patents.
License Agreement
IMPORTANT: CAREFULLY READ ALL THE TERMSAND CONDITIONS OF THIS AGREEMENT BEFOREOPENING THE PACKAGE OR PROCEEDING WITHINSTALLATION. OPENING THE PACKAGE OR COM-
PLETING THE INSTALLATION INDICATES YOURACCEPTANCE OF THE TERMS AND CONDITIONSCONTAINED IN THIS AGREEMENT.
IF YOU DO NOT AGREE TO THE TERMS AND CON-DITIONS CONTAINED IN THIS AGREEMENT,CANCEL ANY INSTALLATION AND PROMPTLYRETURN THIS PRODUCT AND THE ASSOCIATEDDOCUMENTATION TO CSI, AND YOUR MONEYWILL BE REFUNDED. NO REFUNDS WILL BE GIVENFOR PRODUCTS WITH DAMAGED OR MISSINGCOMPONENTS.
Definition of Software
As used herein, software refers to any computer pro-
gram contained on any medium. Software includesdownloadable firmware for use in devices such as ana-lyzers or MotorStatus units and it includes computerprograms executable on computers or computer net-works.
Software License
You have the non-exclusive right to use this software on
only one device at a time. You may back-up the soft-ware for archival purposes. For network systems, youhave the non-exclusive right to install this software ononly one server. Read/write access is limited to the num-ber of concurrent use licenses purchased. The numberof guest-only accesses is up to a maximum of 250.
CSI grants you a non-exclusive right to use the Software
solely for your own internal data processing operationson the CSI designated supported operating platform for
up to any applicable maximum number of licensedusers. You may not relicense the Software or use theSoftware for third party training, commercial time shar-
ing, rental, or service bureau use. Client may not use theSoftware in, as, or with an ASP (Application Service Pro-vider).
Software Updates
CSI agrees to provide you, at no charge except formedia, preparation and shipping charges, for one (1)year from the date of purchase, all updates to the soft-
ware made at the sole discretion of CSI. Should you pur-chase a software support agreement for the nextsucceeding year following the first year from the date ofpurchase, and thereafter on an annual basis, and if CSIis still providing support, you may purchase the same,annually, at the then existing rate..
Updates/Upgrades
Upon receipt of new CSI software replacing older CSIsoftware, you have 30 days to install and test the newCSI software on the same or a different device. At theend of the 30-day test period, you must both removeand return the new CSI software or remove the older CSIsoftware.
Ownership
The licensed software and all derivatives are the soleproperty of Computational Systems, Inc. You may notdisassemble, decompile, reverse engineer or otherwisetranslate the licensed program. You may not distributecopies of the program or documentation, in whole or inpart, to another party. You may not in any way distort, orotherwise modify the program or any part of the docu-mentation without prior written consent from CSI.
Transfer
You may transfer the software and license to anotherparty only with the written consent of CSI and only if theother party agrees to accept the terms and conditions ofthis Agreement. If you transfer the program, you musttransfer the documentation and any backup copies ortransfer only the documentation and destroy anybackup copies.
8/6/2019 Laser Alignment 97191
4/394iv
Copyright
The software and documentation are copyrighted. Allrights are reserved.
Termination
If you commit a material breach of this Agreement, CSImay terminate the Agreement by written notice.
Virus Disclaimer
CSI uses the latest virus checking technologies to test allits software. However, since no antivirus system is100% reliable, we strongly advise that you use an anti-
virus system in which you have confidence to verify thesoftware is virus-free. CSI makes no representations orwarranties to the effect that the licensed software isvirus-free.
NO WARRANTY
THE PROGRAM IS PROVIDED "AS-IS" WITHOUTANY WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING BUT NOT LIMITED TO ANYWARRANTIES OR MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE.
LIMITATION OF LIABILITY AND REMEDIES
IN NO EVENT WILL CSI BE LIABLE TO YOU OR ANY
THIRD PARTY FOR ANY DAMAGES,INCLUDING ANY LOST PROFITS, LOST SAVINGS,OR OTHER INCIDENTAL OR CONSEQUENTIALDAMAGES ARISING OUT OF THE USE OR THEINABILITY TO USE THIS PROGRAM.
THE LICENSEE'S SOLE AND EXCLUSIVE REMEDY INTHE EVENT OF A DEFECT
IN WORKMANSHIP OR MATERIAL ISEXPRESSLY LIMITED TO THE REPLACEMENT OFTHE DISKETTES OR OTHER MEDIA. IN NOEVENT WILL CSI'S LIABILITY EXCEED THE PUR-CHASE PRICE OF THE PRODUCT.
Export Restrictions
You agree to comply fully with all laws, regulations,
decrees and orders of the Unites States of America thatrestrict or prohibit the exportation (or re-exportation) of
technical data and/or the direct product of it to othercountries, including, without limitation, the U.S. ExportAdministration Regulations.
U.S. Government Rights
When provided to the U.S. government, the computersoftware and related materials and documentation areprovided subject to the same license rights as those enu-merated above.
Hardware Technical Help
1. Please have the number of the current version of
your firmware ready when you call. The versionof the firmware in Emerson Process ManagementsCSI 2100 series, CSI 2400, and other analyzersappears on the power-up screen that is displayedwhen the analyzer is turned on.
2. If you have a problem, explain the exact nature ofyour problem. For example, what are the errormessages? When do they occur? Know what youwere doing when the problem occurred. Forexample, what mode were you in? What steps didyou go through? Try to determine before you callwhether the problem is repeatable.
Hardware Repair
Emerson Process Management repairs and updates itshardware products free for one year from the date ofpurchase. This service warranty includes hardware
improvement, modification, correction, recalibration,update, and maintenance for normal wear. This servicewarranty excludes repair of damage from misuse,abuse, neglect, carelessness, or modification performedby anyone other than Emerson Process Management.
After the one year service warranty expires, each returnof a Emerson Process Management hardware product issubject to a minimum service fee. If the cost of repairexceeds this minimum fee, we will call you with an esti-mate before performing any work. Contact EmersonProcess Managements Product Support Department forinformation concerning the current rates.
8/6/2019 Laser Alignment 97191
5/394
v
Obsolete Hardware
Although Emerson Process Management will honor allcontractual agreements and will make every effort to
ensure that its software packages are backward com-patible, to take advantage of advances in newer hard-ware platforms and to keep our programs reasonablysmall, Emerson Process Management reserves the rightto discontinue support for old or out-of-date hardwareitems.
Software Technical Help
1. Please have the number of the current version of
your software ready when you call. The versionnumber for software operating under Windows isdisplayed by selecting About under the Helpmenu bar item.
2. If you have a problem, explain the exact nature ofyour problem. For example, what are the errormessages? (If possible, make a printout of the errormessage.) When do they occur? Know what you
were doing when the problem occurred. Forexample, what mode were you in? What steps didyou go through? Try to determine before you callwhether the problem is repeatable.
3. Please be at your computer when you call. We canserve you better when we can work through theproblem together.
Software Technical Support
Emerson Process Management provides technical sup-port through the following for those under supportagreement:
Telephone assistance and communication via theInternet.
Mass updates that are released during that time.
Interim updates upon request. Please contactEmerson Process Management Product Support formore information.
Returning Items
1. Call Product Support (see page 2) to obtain a returnauthorization number. Please write it clearly and
prominently on the outside of the shippingcontainer.
2. If returning for credit, return all accessoriesoriginally shipped with the item(s). Include cables,software diskettes, manuals, etc.
3. Enclose a note that describes the reason(s) you arereturning the item(s).
4. Insure your package for return shipment. Shipping
costs and any losses during shipment are yourresponsibility. 7COD packages cannot beaccepted and will be returned unopened.
8/6/2019 Laser Alignment 97191
6/394
vi
8/6/2019 Laser Alignment 97191
7/394
vii
ContentsHow To Use This Manual 1-1
Emphasis Paragraphs 1-5
Analyzer Serialization 1-5
UltraMgr Software and Prerequisites 1-6
Standard Equipment 1-7
Fixtures Case Layout (bottom section) 1-7
Fixtures Case Layout (top section) 1-8
Chapter2 Setting Up and Using Laser Alignment Fixtures
Models 821500 and 822500 RF Laser Systems Only 2-4
General Description 2-5
Sensor Head Description 2-5
General Maintenance 2-10
Care and Handling 2-10
Calibration 2-10
Battery Charging 2-11
Battery Usage - Laser Heads 2-16
Precautions 2-17
Introduction to Laser Alignment Fixtures Setup 2-18
Attaching the Fixtures 2-19
Attaching the B821007 Carbon Steel Mounting Base 2-19
Attaching Chain to the Chain Pickup 2-20
Allowing Maximum Tightening Range 2-21
Positioning a Mounting Base 2-22
Positioning the Other Mounting Base 2-23
Attaching Excess Chain 2-24
Using the Chain Clip 2-26
Installing a Post 2-27
Mounting a Sensor Head 2-28
Models 821500 and 822500 RF Laser Systems Only 2-30
Mounting the Other Sensor Head 2-31
Communication Between the Fixtures and Analyzer 2-32
Connecting the 8000RF Interface 2-34
8/6/2019 Laser Alignment 97191
8/394
viii
Turn the Laser Beams On 2-40
Center the Laser Beams 2-41
Rough Alignment of the Laser Beams 2-42
Introduction to Special Applications 2-46
Using Additional Mounting Blocks 2-47
Adding a 2-inch (51 mm) Block 2-48
Mounting One Bracket on a Coupling 2-50
Mounting on Shafts (or Couplings) > 8-inch
(203 mm) Diameter 2-51
Using Alternative Mounting Brackets 2-52
Chapter3 Horizontal Alignment
Help 3-1
Basic Alignment Steps 3-1
Advanced and Basic Laser Align Applications 3-2
Advanced Laser Align 3-2Basic Laser Align 3-2
Main Screen 3-3
Three Step Alignment 3-5
Main Screen Function Keys 3-6
Alt Main Screen 3-7
Alt Main Screen Function Keys 3-8
Job Reset 3-11
Basic Mode 3-12
Basic Mode Function Keys 3-13
Job Reset 3-16
Machine Configuration Function Keys 3-18
Laser Align (Alignment) Method Function Keys 3-20
Tolerance Type 3-22
Tolerance Type Function Keys 3-22
Laser Configuration Function Keys 3-24
Laser Address Selection 3-26
Check Lasers 3-30
Laser Head Status Function Keys 3-32
Job Manager 3-34
8/6/2019 Laser Alignment 97191
9/394
ix
Job Manager Function Keys 3-35
Edit Job Setup 3-38
Edit Job Setup Function Keys 3-39
Job Flow 3-42Job Flow Function Keys 3-43
Enter Dimensions 3-45
Entering Fractions 3-51
Quick Spec 3-53
Entering Thermal Growth Information 3-56
Growth at Feet 3-57
Growth at Profile 3-59
Gap/Offset 3-64
Face/Rim 3-68
Reverse Dial 3-72
Sweep Laser Heads 3-75
Foot Pre-Check 3-76
Foot Pre-Check Function Keys (after the Foot Pre-Check
has been started) 3-82
Acquiring Alignment Data 3-82Auto Sweep 3-85
Manual Sweep 3-94
Accept Readings key 3-97
Auto 4 Point 3-100
Manual 4 Point 3-105
Dual Pass 3-111
Dual Pass Cable (8215C2-PM) - Models 821500and 822500 Only 3-119
Review Results 3-121
Review Results (Measurements) Function Keys 3-124
Sweep Mode Curve Data 3-126
Data Quality 3-127
Move Machine 3-129
Vertical Move 3-130
Vertical Move Function Keys 3-132Horizontal Move 3-135
Horizontal Move Function Keys 3-137
Dual Move 3-140
Extra Foot Calculation 3-143
Predict Mode 3-145
Prediction Function Keys 3-149
Live Move 3-149
8/6/2019 Laser Alignment 97191
10/394
x
Data Detail (Tolerance Plots) 3-162
Data Detail (Tolerance Plot) Function Keys 3-166
Display Sine Fit 3-168
Display Sine Fit Function Keys 3-172View Data 3-174
C-face Alignment 3-175
Notes 3-180
Notes Function Keys 3-180
Transferring Alignment Job Data and Tolerances 3-184
Tolerances 3-193
UltraMgr/2130 Laser Align Overview 3-194Case Studies 3-195
UltraMgr 3-199
UltraMgr Software and Firmware Prerequisites 3-200
Tolerances 3-201
Chapter4 Vertical AlignmentHelp 4-3
Basic Vertical Alignment Steps 4-3
Three Step Alignment 4-5
Vertical Main Screen Function Keys 4-6
Vertical Alt Main Screen 4-7
Vertical Alt Main Screen Function Keys 4-8
Job Reset 4-10Vertical Machine Configuration 4-11
Vertical Machine Configuration Function Keys 4-12
Laser Angle Advance 4-13
Laser Angle Advance Function Keys 4-14
Vertical Laser Configuration 4-15
Vertical Laser Configuration Function Keys 4-16
Vertical Enter Dimensions 4-17Define Flange 4-21
Define Flange Function Keys 4-23
Custom Pattern 4-25
Custom Pattern Function Keys 4-27
Vertical Sweep Laser Heads 4-29
Vertical Move Machine 4-38
Angular Move 4-39
Angular Move Function Keys 4-40
8/6/2019 Laser Alignment 97191
11/394
xi
Offset Move 4-41
Offset Move Function Keys 4-44
Vertical Data Detail (Tolerance Plots) 4-45
Chapter5 Straightness Measurements
Straightness Main Screen 5-3
Three Step Straightness Measurements 5-4
Straightness Main Screen Function Keys 5-5
Straightness Alt Main Screen 5-6
Straightness Alt Main Screen Function Keys 5-6Straightness Laser Configuration 5-9
Straightness Laser Configuration Function Keys 5-10
Straightness Enter Dimensions 5-11
Straightness Move Laser Heads 5-15
Straightness Surface Profile 5-18
ChapterA Application Information
Alignment Application Notes A-3
Pre-job Preparation and Setup A-5
Changes That Occur During Operation A-6
Alignment Pitfalls A-8
AppendixB Foot Pre-Check Types
Foot Pre-Check Measurement Methods Soft Foot and
Frame Distortion Index (FDI) B-1
AppendixC Technical Specifications
Mounting Posts (part number D23465) for Alignment Brackets C-3
AppendixD Accessories and Optional Products
Optional Items for Laser System D-1
Other Accessories D-1
Recommended Spare Parts* D-2
Analyzer Travel/Carrying Cases D-2
8/6/2019 Laser Alignment 97191
12/394
xii
Batteries/Analyzer Chargers D-2
Alignment Fixtures D-2
Customer Support D-3
Reliability Services D-4
Glossary
Index
Chapter 1
8/6/2019 Laser Alignment 97191
13/394
C p
1-1
1
Read This First
How To Use This Manual
This manual is arranged in the following manner:
Chapter 1 read this chapter before attempting to use the Model 2130Laser Alignment program or before proceeding to subsequent chapters.
Chapter 2 lists and describes the various components that make up thelaser alignment system.
Chapter 3 provides general application overview information about pro-cedures used in horizontal shaft alignment.
Chapter 4 provides general application overview information about pro-
cedures used in vertical shaft alignment. Chapter 5 describes how to perform straightness measurements.
Appendix A provides general application overview information about pro-cedures used in shaft alignment.
Note
This manual covers information specific to the 2130 RBMConsultantPro Advanced Laser Alignment program.
It is assumed that the user is familiar with the general hardware andoperation of the Model 2130 analyzer. If any questions or concernsarise in using the analyzer, refer to the 2130 RBMConsultant Pro,Dual-Channel Machinery Analyzer manual (part number 97017).
Appendix B provides descriptions of Foot Pre-Check types and theiradvantages and disadvantages.
Appendix C details the technical specifications for the Model 8215/8225laser alignment fixtures.
Appendix D describes the various accessories and optional products thatare available for use with the Laser Align application.
8/6/2019 Laser Alignment 97191
14/394
1-2
Note
In this manual, 8215 and 8225 (sometimes quoted as 8215/
8225) refer to both the RF versions (Models 821500 and 822500)and the direct-connect only versions (Models 821501 and 822501 )laser systems except where information specific to one type of lasersystem is discussed.
8/6/2019 Laser Alignment 97191
15/394
1-3How To Use This Manual
Introduction
The UltraSpec Pro 8215/8225 Laser Alignment Fixtures are the latest in a com-plete line of alignment equipment provided by Emerson Process Management.The 8215/8225 system is used in conjunction with the Model 2130 Laser Align pro-gram. Although the Model 2130 analyzer can be purchased separately, it must beused to process the data from the fixtures. The Model 8215/8225 system attachessensor heads to shafts which are typically coupled. Laser beams are emitted fromeach sensor head and targeted on the opposite sensor head. Each shaft position is
measured in relation to the other shaft by rotating the two shafts. Shaft misalign-ment is calculated from the position of each laser beam on its respective target, at arange of angular positions of the laser heads.
The position of each laser beam on its target transmits from each sensor head tothe Model 2130 analyzer through radio frequency (RF) or direct cable communi-cation, depending on the model. The Model 2130 analyzer processes the data and
calculates the required machine moves necessary to bring the machine compo-nents into alignment.
With most alignment systems available today, the sag of the alignment fixtures mustbe considered to accurately calculate machine moves. With the use of laser beams,there is no fixture sag to consider! The RF communication between the sensorheads and the Model 2130 analyzer simplifies data acquisition and reduces oper-ator error. The direct cable connect provides an alternate method to transfer data
when the RF link is not practical.
Since each head has a self-contained inclinometer and additional memory, thedata can be acquired through a variety of methods. Choices range from the tradi-tional top, bottom, left, and right locations (minimum of three) - where the fixturesinteract directly with the analyzer to the patented partial sweep method (the sensorheads memorize the data and later dump it to the analyzer).
When the 8215/8225 fixtures and the 2130 Laser Align program are used with theUltraMgr PC software program, a complete alignment program can be managedfrom a centralized location. UltraMgr provides job tracking, control of alignmenttolerances, alignment history and much more.
8/6/2019 Laser Alignment 97191
16/394
1-4
Some advantages of the UltraSpec Pro 8215/8225 Laser Alignment Fixtures are:
Easy setup
No fixture sag Visible laser to assist with rough alignments
Large diameter mounting range
Large span range between sensor heads
Large vertical expansion to clear larger couplings
Large misalignment measurement range Partial revolutions (down to 45)
Dual Pass method for uncoupled alignments
Real time machine move monitoring, vertical and horizontal
Soft foot locator
Radio frequency communication Direct cable connect, if needed
Automatic data acquisition
Dual beam technology
Internal angle sensors
Internal memory
45-minute charge cycle for sensor heads
Simultaneously charging, sensor heads and analyzer
Best ambient light protection
Vertical machine alignment
Straightness measurement
8/6/2019 Laser Alignment 97191
17/394
1-5How To Use This Manual
Emphasis Paragraphs
Two different types of paragraphs are used throughout this manual to call attentionto the adjacent text:
Note
The note paragraph indicates special comments or instructions.
Caution!The caution paragraph alerts you to actions that may have a major impact,such as lost data or damage to the analyzer or its accessories.
Warning!
The warning paragraph warns you of actions that could cause seriouspersonal injury or death.
Analyzer Serialization
The loaded firmware has been serialized and is matched to the analyzer serialnumber. If the firmware and analyzer serial numbers do not match, contactProduct Support.
8/6/2019 Laser Alignment 97191
18/394
1-6
UltraMgr Software and Prerequisites
NoteYour AMS Suite: Machinery Health Manager software andModel 2130 RBMCONSULTANT PROmust have compatible software.
Requirements
Model 2130 RBMCONSULTANT PRO firmware version v.6.3.8.0 or later.
The following, 4.90 or later, AMS Suite: Machinery Health Manager files -dated 08/08/2005 or later:
RBMcom.exe
RBMcomSr.exe
XFrAlg.dll
UltraAlg.exeUltraMgr requires some planning and setup before jobs can be down-loaded intothis alignment program. Refer to the appropriate UltraMgr users manual for moreinformation on communicating with the PC.
8/6/2019 Laser Alignment 97191
19/394
1-7Standard Equipment
Standard Equipment
When checking the kit to ensure that everything ordered was shipped, comparethe contents of the package to your shipping invoice. For additional assistance,refer to the following fixtures case layouts. If a discrepancy is found, call EmersonCustomer Support at (865) 671-4274.
Fixtures Case Layout (bottom section)
Note
Some parts shown in these illustrations may be optional in differentpackages.
8/6/2019 Laser Alignment 97191
20/394
1-8
Fixtures Case Layout (top section)
Chapter 2
8/6/2019 Laser Alignment 97191
21/394
2-1
Setting Up and Using Laser Alignment Fixtures
Special Instructions About the 8215/8225 Laser Fixtures
Warning!
Prior to mounting the laser alignment fixtures on machine shafts, allswitches operating the machines should be locked out (followlockout procedures for your facility). On completion of the align-ment, inspect the work area to ensure that all equipment is clear ofrotating shafts and couplings, prior to removal of the lockout protec-tion.
Warning!
The 8215/8225 Laser Alignment Fixtures use a Class II (CDRH) laseror Class 2 (IEC) laser. This laser complies with 21 CFR 1040.10 and1040.11 safety requirements with a power output < 1.0 mW (average)and a pulse repetition of 600 pulses/sec. The pulse duration is
8/6/2019 Laser Alignment 97191
22/394
2-2 Setting Up and Using Laser Alignment Fixtures
Laser heads, front view
Laser heads, rear view
8/6/2019 Laser Alignment 97191
23/394
2-3
Note
Only the Models 821501 and 822501 direct-connect only laser sys-
tems have CE approval.
Laser radiation caution
8/6/2019 Laser Alignment 97191
24/394
2-4 Setting Up and Using Laser Alignment Fixtures
Models 821500 and 822500 RF Laser Systems Only
Note
Operation is subject to the following two conditions: (1) this devicemay not cause interference, and (2) this device must accept any inter-ference, including interference that may cause undesired operationof this device.
Note
This equipment has been tested and found to comply with the limitsfor a Class A digital device, pursuant to Part 15 of the FCC Rules.These limits are designed to provide a reasonable protection againstharmful interference when the equipment is operated in a commer-cial environment. This equipment generates, uses, and can radiateradio frequency energy and, if not installed and used in accordancewith the instruction manual, may cause harmful interference to radiocommunications. Operation of this equipment in a residential area islikely to cause harmful interference in which case the user will berequired to correct the interference at his own expense.
Caution!
Changes or modifications not expressly approved by Emerson could void theuser's authority to operate the equipment.
Caution!
This device has been designed to operate solely with the antenna type provided,Emerson part number 88200. An antenna having a higher gain is strictly pro-hibited per regulations of Industry Canada.
8/6/2019 Laser Alignment 97191
25/394
2-5General Description
General Description
Sensor Head Description
This section describes both the old and current versions of the 8215/8225 laserheads. The older version of heads can be identified by their gray front panels andblack grid lines. The current version of heads have different color front panels.Head A has a gray front panel with white grid lines and blue on/off buttons, while
head B has a blue front panel with white grid lines and gray on/off buttons.
Note
Throughout the manual, photos may contain images of either theolder or current versions of laser heads.
1
RF Antenna
RF AntennaHousing
DirectConnectPort
Targets(PSDs)
SensorHead ID
LaserSource
ChargingPort
HorizontalLaserAdjustment
VerticalLaserAdjustment
PowerButton
PostGrip
ActivityLED
Laser HeadModel #
8/6/2019 Laser Alignment 97191
26/394
2-6 Setting Up and Using Laser Alignment Fixtures
The sensor head with the laser source on top is the Master head (known as headA). The other head is the Slave (known as head B). The model number is listedon the back of each head. They can be identified by the letter A or B on the front.
There are no differences between the older and current versions of the 8215/8225laser heads with the exception of the front panels and batteries. The older versionis powered by nickel cadmium (NiCad) batteries, while the current version is pow-ered by Nickel Metal Hydride (NiMH) batteries.
The difference between the Model 8215 sensor heads and the 8225 sensor headsare the target (Position Sensing Detector or PSD) size, laser distance, and the front
overlay. The 8215 sensor head has a 10mm x 10mm PSD and a laser which allowsalignments over a sensor spacing up to 30 feet, or 9 meters. The 8225 sensor headhas a 20mm x 20mm PSD and a laser which allows alignments over a sensor spacingup to 100 feet (30.5 meters).
Although the direct-connect only laser system (Model 821501 and 822501) is notillustrated in this manual, the only difference between it and the RF laser system(Models 821500 and 822500) is that the RF system transmits information using
either the RF or direct-connect communication. The direct-connect only lasersystem uses only the direct-connect communication. For this reason, the direct-con-nect only laser systems do not have an RF antenna or antenna housing.
8/6/2019 Laser Alignment 97191
27/394
2-7General Description
The Activity LED on the front panel can be red, yellow, or green. An explanationof their meaning is shown in the following table.
Table 1:
LED Status Meaning Required Action
Green Yellow Red
X
Normal Operation - When theLaser Head systems are allfunctioning properly and the
laser beam from the companionLaser Head is striking the PSD inthe linear region. This is thedesired state. The Laser Head isin the acceptable condition toperform an alignment.
No Action Required
X (flashing)
Sensor head in standby (sleep)mode - When the Laser Headsees no activity for five minutes,they automatically enter SleepMode to conserve batterypower. The color will be theone that was active, solid or
flashing, before this state wasentered. When this sleep modeis entered, the LED will beflashed off for 1.5 sec. and onfor 0.5 sec.
Use analyzer to wake up whenneeded by initiatingcommunication with the laserheads.
X
Minor Error* Refer to (6) Laser Head StatusScreen on page 3-16 for moreinformation on the error and the
required action.
http://chapter_4.pdf/http://chapter_4.pdf/http://chapter_4.pdf/http://chapter_4.pdf/8/6/2019 Laser Alignment 97191
28/394
2-8 Setting Up and Using Laser Alignment Fixtures
* If a minor error is present, the data being acquired may be marginal. The dataquality will depend on the error. If a major error is present, then some kind of hard-ware or system problem exists. Therefore, the data being acquired is rejected.
X (flashing)
Low battery 1st warning (sensorhead) - The Laser Head has theability to monitor its ownbattery power. The batterypower is checked periodicallyto determine if it is below theminimum acceptable power.When the battery powerreaches 4.8 volts, the LED willbe flashed off for 0.5 sec. andthen flashed on for 0.5 sec. Datais accepted when the battery isthis state.
Recharge sensor heads.
X
Major Error* Refer to (6) Laser Head Status
Screen on page 3-16 for moreinformation on the error and therequired action.
X (flashing)
Low battery 2nd/final warning(sensor head) - The Laser Headhas the ability to monitor itsown battery power. The battery
power is checked periodicallyto determine if it is below theminimum acceptable power.When the battery powerreaches 4.2 volts, the LED willbe flashed off for 0.5 sec. andthen flashed on for 0.5 sec. Datais not accepted when the battery
is this state.
Recharge sensor heads.
Table 1:
LED Status Meaning Required Action
Green Yellow Red
http://chapter_4.pdf/http://chapter_4.pdf/http://chapter_4.pdf/http://chapter_4.pdf/8/6/2019 Laser Alignment 97191
29/394
2-9General Description
LED Functionality Difference Due to Dual Pass mode
The functionality of the LED differs slightly from the states described in the abovetable when the Dual Pass mode of operation is selected. The difference lies in the
LED state when the companion Laser Heads laser beam is on the PSD. In Dual Passmode, when the laser beam is on or off of the PSD the LED will be a solid yellow,even when the beam is in the linear portion of the PSD. The beam will then flashto green whenever a valid data point is acquired. This deviation is necessary to allowfor the indication to the user that the Laser Heads are acquiring data as they arerotated past each other.
NoteTo determine the actual error, select the Check Lasers option on theAlt screen. This will activate the Laser Heads Status screen. If an errorcondition actually exists, its type will be shown in a popup windowwithin 60 seconds. Refer to the Check Lasers section for more infor-mation.
8/6/2019 Laser Alignment 97191
30/394
2-10 Setting Up and Using Laser Alignment Fixtures
General Maintenance
Care and Handling
To ensure satisfactory service from this system, follow these procedures:
Keep the mounting base and chain mounting posts lightly oiled to preventthem from corroding.
To maintain repeatability and accuracy, avoid dropping fixture items. Referto the Customer Assistance section for repair, update, and calibration.
Do not subject system items to large temperature swings.
Do not engrave on the sensor heads.
Keep all lens free of grease, dirt, oil, and other smudges.
Clean the laser and target lens with a soft, lint-free cloth and standard lens
cleaning solution (a field size cleaner container is available from Emerson).Never use an organic solvent such as a thinner or benzine.
Store sensor heads in protective hard-shell carrying case when not in use.
Calibration
The Model 8215/8225 calibration should be checked every two years. Return thesensor heads to Emerson for a calibration check. All calibrations are NIST trace-able.
Caution!
Donotremove the CSI Quality label on the back of the sensor head. Thiswillvoidyour warranty.
8/6/2019 Laser Alignment 97191
31/394
2-11General Maintenance
Battery Charging
Batteries must be charged with the Model 8211charger. The Model 8211 charger
is a smart, drop-in charger that can provide a fast- or trickle-charge for the laserheads and analyzer.
This section describes both the old and current version of the 8211 charger. Theolder version of the 8211 charger can be identified by its solid gray front panel. Thecurrent version of the 8211 charger also uses a gray motif on the front panels, butthe area around the Fast and Discharge buttons is blue.
Model 8211 Smart Charger
The Model 8211 charger provides all battery charging needs and comes with thesystem. It is a smart, drop in charger for the laser heads; it will also charge the ana-lyzer when plugged into a cable. The following picture shows both of the laserheads andthe analyzer being charged.
Charging the Sensor Heads and Analyzer with Model 8211 Charger.
8/6/2019 Laser Alignment 97191
32/394
2-12 Setting Up and Using Laser Alignment Fixtures
The current version of the 8211 charger will charge both the former and currentversions of the 8215/8225 laser heads but at a slower charge rate than the older ver-sion of the 8211 charger. The former version of the 8211 charger charges the
former version of the 8215/8225 laser heads, but it will only trickle charge the cur-rent version of the 8215/8225 laser heads. Although no damage will occur if theFast Charge cycle is initiated, this cycle will not work for the current version of thelaser heads.
To set up the 8211 charger, complete these steps:
1. . . plug the power cord into the power supply,
2. . . plug the power cord into an AC receptacle,3. . . plug the power supply into the 8211 charger in the top end cap.
At that time, the beeper will sound indicating that power has been applied to thebattery charger. As a test, all LEDs will illuminate for 1.5 seconds.
4. . . Plug the analyzer charging cable into the bottom end cap.
The sensor heads and analyzer can now be charged either individually or, all at thesame time.
Charging the Sensor Heads with the Model 8211 Charger
Drop them over the posts so that the head faces outward as shown in the previousillustration. Heads can be charged individually or together.
Indicator Light Charging Status
Pending Waiting for safe voltage andtemperature
Discharge (steady) Batteries discharging
Discharge (flashing) Discharge requested, waitingfor safe voltage or temperature
Fast (steady) Batteries in fast charge
Fast (flashing) Fast charge requested, waitingfor safe voltage or temperature
Trickle Batteries in trickle charge,topping-off, or charge complete
8/6/2019 Laser Alignment 97191
33/394
2-13General Maintenance
Note
The discharge cycle is intended for older versions of the laser heads,
powered by Nickel Cadmium (NiCad) batteries. This function is notrequired for the current version of the laser heads, powered by NickelMetal Hydride (NiMH) batteries. However, use of this function onlaser heads with NiMH batteries will not result in any damage to theheads or charger.
For maximum safety, the battery charger has a Pending status LED, which lights
momentarily when the head is first placed on the charger. If a battery is very low, oris out of a specific temperature range, it cannot be safely charged. When this con-dition occurs the Pending indicator remains illuminated. While Pending, thecharger is actually charging the batteries at a very low rate in an attempt to chargethe low battery to an acceptable voltage range. Once the battery temperature andvoltage are suitable for charging, the charger automatically begins trickle chargingand the Trickle indicator light turns on.
To fast charge or discharge the battery the Fast button or Discharge button mustbe pressed. If the Fast button or Discharge button is pressed while the batteryvoltage is too low or temperature is not suitable for Fast or Discharge operation, theindicator light will flash on and off. This response acknowledges the request butindicates that the charger cannot fulfill the request at that time. Once voltage andtemperature conditions are suitable, the requested Fast or Discharge operation will
begin and the indicator light will change to a steady light.
Caution!
Note that if the battery is fully charged, a user is able to initiate fast charge bypressing the Fast button. After about 2 minutes, the charger will stop fast chargein this case. However, to avoid overcharging batteries, you should not press theFast button with an already fully charged battery.
8/6/2019 Laser Alignment 97191
34/394
2-14 Setting Up and Using Laser Alignment Fixtures
After the Fast charging cycle has completed, the chargers beeper sounds and thecharger automatically begins trickle charging. When this condition begins, theTrickle indicator light turns on indicating that the battery is almost completely
charged, or is completely charged. For the laser head batteries, the two conditionsoccur within a few minutes of each other. Charge time from a fully discharged setof batteries to approximately a 90% voltage charge is 45 minutes (current versionof the 8211 charger) and 15 minutes for the former version of the 8211 Charger.
If the Discharge cycle has been initiated, on completion the charger automaticallybegins fast charging and the Fast indicator light turns on. If charging a former ver-sion of the laser heads that contain NiCad batteries - to avoid the battery memory
concern use the Discharge mode when you have more than 20 minutes to chargethe sensor head batteries. The typical charge cycle is as follows:
Note
After power has been applied to the charger and the sensor head(s)placed in it, if none of the LED's for that sensor head are lit then thecontact between the sensor head and charger may not be sufficientto charge the batteries. No LED's lit indicates a no battery presentstate. If this takes place, remove the sensor head from the charger andtry reseating it back into the charger.
Action Time
Press DISCHARGE button Start
DISCHARGE complete, FAST starts 7 minutes
FAST complete, TRICKLE starts charging complete 22 minutes
NOTE: The heads can be left on TRICKLE indefinitely (until the next time they areneeded).
8/6/2019 Laser Alignment 97191
35/394
2-15General Maintenance
Note
After a charging cycle begins, if that charging cycle is interrupted (e.g.
disconnecting the power to the charger or removing the sensor headfrom the charger) the charging process described above initiatesfrom the beginning. Therefore, if the charger cycle is interruptedwhile the Fast charge mode is in progress, then the charger automat-ically begins trickle charging after Pending(see below).
The Pending LED lights momentarily and switches into Fast charge. Charge time
for a fully discharged set of batteries is 45 minutes (for the current version of the8211 charger) and 15 minutes for the former version of the 8211 charger. Thebeeper will sound when both heads are fully charged and the charger switches totrickle.
Charging the Analyzer with the Model 8211 Charger
Charging functions for the 8117, 2120 and 2130 analyzers are identical for both the
former and current versions of the 8211 charger.
Plug the charging cable (A821102) from the bottom end cap on the 8211 chargerinto the charger port on the top end cap of the analyzer. The battery pack willrecharge in three hours. After the battery pack has been fully charged, the batterycharger automatically switches to a trickle charge.
8/6/2019 Laser Alignment 97191
36/394
2-16 Setting Up and Using Laser Alignment Fixtures
Battery Usage - Laser Heads
Power is supplied to each sensor head via a rechargeable battery pack. A fullycharged battery pack provides five to six hours of continuous service while transmit-ting data. Longer operation is possible since typical alignments do not require con-tinuous communication with the analyzer. The battery is designed to have a longlife and is not intended to be replaced by the user. Replacement should be per-formed only at Emerson. Emerson recommends that the batteries be replacedafter 500 charges.
To conserve battery life, the 8215/8225 has a sleep mode and a shutdown mode.The sleep mode is activated after 5 minutes of no communication with the analyzer.In the sleep mode, the laser beam and RF communication are shutdown until com-munication is reestablished. All data in memory is saved. In the auto-shutdownmode, the sensor heads are completely shutdown. The Power Button starts thesensor heads again. All data in memory is lost, therefore another sweep should betaken.
The sleep and auto-shutdown modes can be disabled. To disable the sleep modeon each laser head, with the laser heads off, press and hold the Power Buttons. Thiswill cause the laser heads and their corresponding LEDs to power on for approxi-mately two seconds. Then laser heads and their corresponding LEDs will power offfor approximately three seconds. After the laser heads and their correspondingLEDs power back on again, the shutdown mode will be disabled. To re-enable the
sleep mode, just power the heads off.
Note
Please note that this disables the battery conservation (for the sensorheads) therefore, if the heads are left on, the batteries will run down.
8/6/2019 Laser Alignment 97191
37/394
2-17Precautions
Precautions
Please follow these precautions carefully. Any product damage due to these condi-tions may void the warranty.
Use only Emerson-supplied battery chargers that have been approved foruse with the analyzer and Model 8215/8225 laser heads. The use of anyother charger will most likely damage the equipment.
Do not use Emerson battery chargers with anything other than the product
for which they are designed. Do not use the 8211 charger to charge any-thing else!
Do not use any batteries other than those included and/or specified for theanalyzer and 8215/8225 laser heads.
Do not connect a printer directly to the RS232 port located on the top panelof the analyzer.
Do not connect any adapters or accessories to the RS232 port located on thetop panel of the analyzer while the analyzer is turned on.
Do not start the machines being aligned with the laser alignment systemequipment attached. Be sure to remove the laser system before starting themachinery.
8/6/2019 Laser Alignment 97191
38/394
2-18 Setting Up and Using Laser Alignment Fixtures
Introduction to Laser Alignment Fixtures Setup
This section takes you through a step-by-step setup of the 8215/8225 Laser Align-ment Fixtures. Before before beginning the actual machine alignment, be sure allpre-alignment checks have been completed.
Warning!
Prior to mounting the laser alignment fixtures on machine shafts, allswitches operating the machines should be locked out. Follow safety
precautions for your facility. Normally, only personnel performingthe alignment should be able to unlock any startup switch. After analignment has been completed, the work area should be inspected toensure that all equipment is clear of rotating shafts/couplings priorto removal of the lockout protection.
Warning!
The 8215/8225 Laser Alignment Fixtures use a Class II (CDRH) laseror Class 2 (IEC) laser. This laser complies with 21 CFR 1040.10 and1040.11 safety requirements with a power output < 1.0 mW (average)and a pulse repetition of 600 pulses/sec. The pulse duration is
8/6/2019 Laser Alignment 97191
39/394
2-19Attaching the Fixtures
Attaching the Fixtures
This section shows how to attach and secure the mounting base, chains, align thetwo mounting bases by leveling, install the sensor heads, turn on the sensor heads,and center the lasers on their targets.
Attaching the B821007 Carbon Steel Mounting Base
The B821007 3/4 inch (19mm) wide carbon steel mounting bracket is suitable for
the majority of alignment jobs where the laser fixtures can be rigidly mounted to ashaft that can be rotated freely.
Select the chain tightener of choice. The right photograph shows a knurled nutwhich can be tightened by hand. The hex nut mechanism provides a more stable,versatile mounting while the knurled nut is more convenient. Use each nut asshown.
2
These photographs illustrate how the chain assembly should be slipped into themounting base. Hold the chain out away from the base and slip the cylinder into itscradle. To ensure maximum tightening range, each nut should be flush with theend of the tightening bolt.
Standard Nut Knurled Knob
8/6/2019 Laser Alignment 97191
40/394
2-20 Setting Up and Using Laser Alignment Fixtures
Attaching Chain to the Chain Pickup
This photograph illustrates how the chain attaches and actually clamps the shaft.The base is placed on the shaft (or coupling) and a link of the chain is slipped intothe chain pickup to secure the base to the shaft. After slipping a chain link into thechain pickup, tighten the bolt at the end of the chain.
8/6/2019 Laser Alignment 97191
41/394
2-21Attaching the Fixtures
Allowing Maximum Tightening Range
To allow for maximum tightening range, ensure that the chain nut is flush with theend of the chain bolt (as shown by arrow). Notice that the chain bolts are on oppo-site sides. As shown in later sections, each mounting base can be installed on eitherend and the chain bolts placed on either side of the shaft.
P i i i M i
8/6/2019 Laser Alignment 97191
42/394
2-22 Setting Up and Using Laser Alignment Fixtures
Positioning a Mounting Base
Tighten one of the mounting bases and rotate it (along with the shaft) until it issomewhat level at the top of the rotation. To tighten the mounting base, use a 9/16 inchwrench or your hand, depending on which chain tightener is being used.
Caution!Do not overtighten the chain the maximum tightening torque is 10 ft.-lbs.
P iti i th Oth M ti B
8/6/2019 Laser Alignment 97191
43/394
2-23Attaching the Fixtures
Positioning the Other Mounting Base
With the previous mounting base still in its level position, if necessary, loosen androtate the other mounting base until it is somewhat level with it. Tighten this baseand recheck the other base to ensure that both are now level in relation to oneanother.
Although this part of the procedure is not absolutely critical, placing the mounting
bases relatively level with each other allows the laser beam adjustment to be moreor less centered. This ensures that the laser beams can line up with their targetseasily.
Also, there may be times when the top position is not accessible. The objective ofthis step is to mount the sensor heads in the same rotational position. This providesthe maximum rotational range for the sensor during data acquisition.
Attaching Excess Chain
8/6/2019 Laser Alignment 97191
44/394
2-24 Setting Up and Using Laser Alignment Fixtures
Attaching Excess Chain
One of the problems with using chains as a mounting bracket is that the excess
chain flops and can cause errors. CSIs Laser Alignment Fixtures provide solutionsfor this problem.
Two slots are provided (one on either side) to take up the slack. As shown in thefollowing photographs, you can use either or both of the slots as needed. The orderof use is not important. In fact, the L-slot cannot be used when mounting to shafts(or couplings) greater than 3 inches (76 mm) in diameter. When fastening thechain into the T-shaped slot, the rubber block will hold the chain in place.
The photograph below illustrates using the T-shaped slot; see the following page foran example using the L-shaped slot.
Using the T-shaped Slot
8/6/2019 Laser Alignment 97191
45/394
2-25Attaching the Fixtures
Using the L-shaped Slot
Caution!
Do not attach excess chain prior to tightening the mounting base chain bolts.Doing so may cause damage to the L and T-shaped slots.
Using the Chain Clip
8/6/2019 Laser Alignment 97191
46/394
2-26 Setting Up and Using Laser Alignment Fixtures
Using the Chain Clip
You will almost always have a little extra chain left over. In that case, use the chainclip (part number D22745) to attach it to the previous chain loop. Emerson recom-mends that you use this clip to help prevent the chain from sliding out of theL-slot as the shafts are rotated.
Installing a Post
8/6/2019 Laser Alignment 97191
47/394
2-27Attaching the Fixtures
Installing a Post
Screw a mounting post (part number D23465) into each of the outer holes in themounting base. Tighten each post with the supplied tightener (Phillips screw-driver) or with a 1/8 inch Allen wrench (not supplied with kit).
8/6/2019 Laser Alignment 97191
48/394
Note
8/6/2019 Laser Alignment 97191
49/394
2-29Attaching the Fixtures
Longer mounting posts are not available. However, if you wish tomake your own, refer to the mechanical drawing of a mounting post
in the section entitled Mounting Post (part number D23465) ForAlignment Brackets in Appendix B.
Models 821500 and 822500 RF Laser Systems Only
8/6/2019 Laser Alignment 97191
50/394
2-30 Setting Up and Using Laser Alignment Fixtures
Models 821500 and 822500 RF Laser Systems Only
Depending on the clearance around which the laser head will be rotated, the posi-tion of the RF antenna may have to be adjusted. When the antenna is in its mostupright position it extends up above the top of the laser head. Holding the antennahousing (not the antenna itself), rotate or twist the antenna down (or updepending on its starting position) to its desired position. The antennas rotationalarc is 30 degrees. When the antenna is in the down position it does not extendabove the top of the laser head.
3
Mounting the Other Sensor Head
8/6/2019 Laser Alignment 97191
51/394
2-31Models 821500 and 822500 RF Laser Systems Only
Install the opposite sensor head in the same manner (Head A or Head B,depending on which sensor head was mounted on the other side).
Communication Between the Fixtures and Analyzer
8/6/2019 Laser Alignment 97191
52/394
2-32 Setting Up and Using Laser Alignment Fixtures
The analyzer conducts communication with the fixtures via a short-range, low-
power radio frequency (RF) carrier (916.5 MHz) or by cable.Radio Frequency (Models 821500 and 822500 only) - With RF, communicationoccurs in much the same manner as with other short-range wireless systems (forexample, cordless phones) a direct line-of-sight communication is not required.
A typical operating range of up to 50 feet (15 meters) can be achieved using RFcommunication, but this range is greatly influenced by building construction mate-
rials and contents, other radio systems operating in the vicinity at or near the sameoperating frequency, and noise generated by nearby equipment. It is not unusualto achieve four times the typical operating range in electrically quiet environmentor to achieve less than the typical operating range in an electrically noisy environ-ment.
Note
This equipment has been tested and found to comply with the limitsfor a Class A digital device, pursuant to Part 15 of the FCC Rules.These limits are designed to provide a reasonable protection againstharmful interference when the equipment is operated in a commer-cial environment. This equipment generates, uses, and can radiateradio frequency energy and, if not installed and used in accordancewith the instruction manual, may cause harmful interference to radio
communications. Operation of this equipment in a residential area islikely to cause harmful interference in which case the user will berequired to correct the interference at his own expense.
Caution!
Changes or modifications not expressly approved by Emerson could void theuser's authority to operate the equipment.
There may be times when an RF communication between each sensor head andthe analyzer is not convenient. Moving or keeping the analyzer closer to the laserheads can minimize this inconvenience.
The sensor heads have memory for saving alignment readings. If communicationwith the analyzer is broken during rotation (while using the Auto Sweep mode),th di t d i til th b t itt d Wh th
8/6/2019 Laser Alignment 97191
53/394
2-33Models 821500 and 822500 RF Laser Systems Only
these readings are stored in memory until they can be transmitted. When thesensor head is turned off, the memory data is erased.
If the analyzer is out of range of one or both sensor heads or if some sort of RF inter-ference is occurring, it will repeatedly attempt to communicate with the sensorheads. A message will be displayed on the analyzer until the communication link isestablished.
When communication using RF becomes difficult, Emerson recommends that youuse the Direct Connect link as described inDirect Connect (All Models) on page2-36.
Connecting the 8000RF Interface
8/6/2019 Laser Alignment 97191
54/394
2-34 Setting Up and Using Laser Alignment Fixtures
Attaching 8000RF to 25-pin Connector
Install the 8000RF Interface onto the serial port of the analyzer by completing the
following steps:
1. . . Ensure that the Model 2130 analyzer is turned off.
2. . . Connect the 25-pin connector of the 8000RF Interface to the RS-232 port onthe Model 2130 analyzer.
3. . . Turn the Model 2130 analyzer on.
Caution!
Do not rotate or twist the antenna on the 8000RF Interface. Attempting to do so
8/6/2019 Laser Alignment 97191
55/394
2-35Models 821500 and 822500 RF Laser Systems Only
f p gwill damage the unit.
The Attached 8000RF Interface.
Direct Connect (All Models)
Direct Connect is designed for those conditions where it is difficult to communi-cate between the analyzer and the sensor heads using RF Conditions such as
8/6/2019 Laser Alignment 97191
56/394
2-36 Setting Up and Using Laser Alignment Fixtures
cate between the analyzer and the sensor heads using RF. Conditions such asbuilding construction materials and contents, other radio systems operating in thevicinity at or near the same operation frequency, and noise generated by nearbyequipment all may make RF communication unsatisfactory.
Note
Both the A800001 and A821510 Direct Connect cables will work withthe 8215/8225 laser heads for all modes of operation where commu-nication between the laser heads and analyzer are necessary, exceptfor the Dual Pass mode. Only the A821510 cable can be used for theDual Pass mode when using direct-connect communication.
To use Direct Connect, complete these steps:
1. . . Make sure the analyzer is turned off.
8/6/2019 Laser Alignment 97191
57/394
2-37Models 821500 and 822500 RF Laser Systems Only
2. . . Attach the 25-pin connector of the direct connect cable to the RS232 port on
top of the analyzer.3. . . Connect the Lemo connectors of the direct connect cable to the mating
straight Lemo connector on the extension cables, if applicable.
Note
When connecting the Lemo connector to its mating connector, lineup the red dots located on each connector with each other beforecompleting the connections. To complete the connection, push theconnectors together. Do not twist.
4. . . Connect the Lemo connector on the opposite end of the cable to the Lemoport under the nose of each 8215/8225.
NoteWhen connecting the Lemo connector to its mating connector, lineup the red dots located on each connector with each other beforecompleting the connections. To complete the connection, push theconnectors together. Do not twist.
5. . . Turn the analyzer on.From this point on, Direct Connect is very easy to use. The analyzer determines thatit is connected and disables the RF communication (Models 821500 and 822500only). Cables can be unplugged and reconnected at any time (and at any connec-tion). You do not have to remember which cable is plugged to which head. Even ifyou switch the orientation of the cables (when reconnecting), the analyzer canadjust to the change and will still work correctly.
8/6/2019 Laser Alignment 97191
58/394
2-38 Setting Up and Using Laser Alignment Fixtures
4
Caution!When using any cable connector inside the sensor head connector, do not turnor twist the connector. This will shear the cable pins off (inside the connector)totally disabling the sensor head and cable. Pull the cable connector completelyout of the sensor head connector before turning the cable.
The direct connect cable is 5 feet (1.5 m) long with pigtail style cable. Whenstanding between the sensor heads, a 6 feet (1.8 m) span can be aligned,depending on the diameter of the shaft. Extension cables, Model 800002 andModel 800003, are available for longer spans, larger diameter shafts, or if youcannot stand directly in the middle.
The extension cables are eight feet (2.4 meters) long. With two extension cablesand the connection pigtail, the total length is 13 feet (4 meters). When standingbetween the sensor heads, a 22 foot (6.7 meters) span can be aligned, depending
8/6/2019 Laser Alignment 97191
59/394
2-39Models 821500 and 822500 RF Laser Systems Only
on the diameter of the shaft.
5
Note
With the 8215, a maximum distance of 30 feet (9 m) between thelaser heads can be achieved. With the 8225, a maximum distance of100 feet (30.5 m) between laser heads can be achieved.
Turn the Laser Beams On
8/6/2019 Laser Alignment 97191
60/394
2-40 Setting Up and Using Laser Alignment Fixtures
To turn the laser beams on, press the power button on each sensor head. See Bat-tery Usage - Laser Heads on page 2-16 for power button options.
Warning!
Although the laser in the 8215/8225 system is low in intensity (< 1.0mW), never direct the beam at a human eye. Use of controls, oradjustments, or performance of procedures other than those speci-fied by Emerson may result in hazardous laser radiation exposure. Todo so could result in serious personal injury. Always ensure that the
sensor heads are mounted securely before turning on the laser beam.
8/6/2019 Laser Alignment 97191
61/394
Rough Alignment of the Laser Beams
Rough alignment may be required to keep the laser beam on the target as the fix-
8/6/2019 Laser Alignment 97191
62/394
2-42 Setting Up and Using Laser Alignment Fixtures
tures are rotated. Either of these methods can be used: Visible Beam rough alignment utilizes the visible laser beams without the
use of the analyzer
Partial Sweep rough alignment utilizes the partial sweep capabilities of theanalyzer
Visible Beam Rough Alignment
This adjustment must be performed in each of the movement planes (typicallyhorizontal and vertical, when required). A horizontal adjustment is illustrated inthe following figure; duplicate the actions for vertical adjustments.
Rough Horizontal Laser Beam Adjustments
1. Center laser beams
in respective targets
3. Estimate distance
moved by laser beam
Laser beamposition afterheads have
been rotated180
4. Move machine to positionbeams approximately half distanceback toward center of target
2. Rotate laserheads 180
..
The gridlines on the front panel should assist you in determining the approximatemovement(s) needed to rough the machines in. Gridline spacing is 0.3 inches (7.5mm). The following table shows recommended moves based upon the gross move-ment of the laser beam on the sensor head Gross movements are discussed in ver-
8/6/2019 Laser Alignment 97191
63/394
2-43Models 821500 and 822500 RF Laser Systems Only
ment of the laser beam on the sensor head. Gross movements are discussed in ver-
tical terms for simplicity.
6
Gross MovementRecommended Machine Move
8/6/2019 Laser Alignment 97191
64/394
2-44 Setting Up and Using Laser Alignment Fixtures
Note
There will, of course, be combinations of the movements shown inthe previous table. However, these recommendations should providesome general guidelines.
Partial Sweep Rough Alignment
In this method, you must use the fixtures and set the analyzer to Manual Sweep or
Auto Sweep mode. Either method can provide an effective target area much largerthan the 20 mm x 20 mm surface area. If the fixtures can be rotated and bothbeams remain on target greater than 90 (recommended) of the sweep, the analyzercan produce an alignment solution from the data taken. Data gathered from theportion of the sweep that the laser beams were off target is rejected. For more infor-mation about sweep data collection modes, see Chapter 6.
at Gearbox at Motor
Small Large,down
Angular & Offset add shims under the inboardGearbox feet or remove shims from the outboardGearbox feet.
Large,down
Small Angular & Offset add shims under the inboard Motorfeet or remove shims from the outboard Motor feet.
Large, up Large,down
Offset add shims to all feet of the Gearbox or removeshims from all feet of the Motor.
Large,down
Large, up Offset add shims to all feet of the Motor or removeshims from all feet of the Gearbox.
Large, up Large, up Angular add shims under the outboard feet of bothmachines or remove shims from the inboard feet of both
machines.
Large down Large down Angular remove shims from the outboard feet of bothmachines or add shims under the inboard feet of bothmachines.
This procedure also works when using the Dual Pass mode.
Note
Roughing inthemachineso that the laserbeamis keptonthe target
8/6/2019 Laser Alignment 97191
65/394
2-45Models 821500 and 822500 RF Laser Systems Only
Roughing in the machine so that the laser beam is kept on the target(PSD) as the laser fixtures are rotated can be quicker with a largerPSD (e.g. with the 20x20mm PSD on the 8225 laser fixtures).
Introduction to Special Applications
This section covers using additional mounting blocks, mounting on large diame-
8/6/2019 Laser Alignment 97191
66/394
2-46 Setting Up and Using Laser Alignment Fixtures
g g , g gters ( shafts > 8 inches (203 mm), and using alternative mounting brackets. Nor-mally, additional blocks are used to achieve greater coupling clearance. In somecases, you may find that one (or both) of the mounting blocks must be installed onthe coupling itself. For larger diameter shafts (or mounting on a coupling), addi-tional lengths of chain may also be needed to mount the base.
8/6/2019 Laser Alignment 97191
67/394
Adding a 2-inch (51 mm) Block
8/6/2019 Laser Alignment 97191
68/394
2-48 Setting Up and Using Laser Alignment Fixtures
This is a picture of a 2-inch (51 mm) block being attached on top of the 1-inch (25
mm) block (the blocks can be stacked in either order).
8/6/2019 Laser Alignment 97191
69/394
2-49Using Additional Mounting Blocks
7
This shows the complete 3-inch (76 mm) extension setup. The following table listswhich blocks are to be used for the various vertical extension ranges.
For Vertical ExtensionLength (inches)
Use These Block(s)(inches)
0 0
1 1
2 2
3 1, 2
Mounting One Bracket on a Coupling
8/6/2019 Laser Alignment 97191
70/394
2-50 Setting Up and Using Laser Alignment Fixtures
If at all possible, Emerson recommends that you mount the brackets on the shafts.However, this is not always possible. Occasionally, you may have to mount thebracket on a coupling.
This view shows the B821007 carbon steel mounting brackets being mounted tothe shaft on one side and the coupling on the other. In order to do this, you mayhave to use a vertical extension block(s). In the example shown above, a 1-inch (25
mm) extension block is being used on the right side; no block is used on the left(coupling) side.
Mounting on Shafts (or Couplings) > 8-inch (203 mm) Diameter
Although the mounting base itself can be used on shaft diameters up to 26 inches(660 mm), additional section(s) of chain must be used for applications greaterh 8 i h (203 ) i di E ll i l h i f
8/6/2019 Laser Alignment 97191
71/394
2-51Using Additional Mounting Blocks
than 8 inches (203 mm) in diameter. Emerson sells extension lengths in two-feetchain increments for the B821007 carbon steel mounting bracket (part numberD22773) and the A800052 soft-mount (non-rotational) mounting bracket (partnumber A832001). In addition to the chain itself, extension kits include a clevis pinand a hair pin, which are used to connect the sections of chain together.
Refer to the following table to determine chains needed with various shaft diame-
ters.
For Shaft Diameters Inches(mm)
Use These Chain Lengths
Less than 8 (203) Standard Chain Length
8 - 15 1/2
(203 394)
Standard Chain Length +
1 Optional Length
15 1/2 23(394 584)
Standard Chain Length +2 Optional Lengths
23 26(584 660)
Standard Chain Length +3 Optional Lengths
Using Alternative Mounting Brackets
Attaching the A800052 Soft-Mount (Non-Rotational) Mounting Base
Th A800052 f b k d l df hi i h h f
8/6/2019 Laser Alignment 97191
72/394
2-52 Setting Up and Using Laser Alignment Fixtures
The A800052 soft mount bracket was developed for machines with shafts or rotorsthat are too large and heavy or difficult to turn like cement kilns, rock crushers,gearboxes and hammer mills. This bracket is typically used for uncoupled align-ments where either the Manual Sweep or Dual Pass methods are being used. It haseight shielded ball bearings mounted at the base of the bracket so that the bracketactually rolls around the shaft.
Nylon nuts that come in the package can be added to the chain to allow it to easilyslide over the shaft while providing a stable mounting configuration. If necessary,install the nylon nuts through slots in the chain using the 6-32 x 1/2 inch panheadscrew (provided) so that they are evenly spaced.
8
Before using, inspect the soft mount base to ensure that all eight ball bearings aretight and free of play. Screw the mounting posts into each hole in the mountingbase and tighten with the supplied tightener (Phillips screwdriver) or with a 1/8inch Allen wrench (not supplied with kit). Select the chain tightener of choice
(refer to Attaching the B821007 Carbon Steel Mounting Base on page 2 19 for
8/6/2019 Laser Alignment 97191
73/394
2-53Using Alternative Mounting Brackets
(refer to Attaching the B821007 Carbon Steel Mounting Base on page 2-19 formore information). The hex nut mechanism provides a more stable, versatilemounting while the knurled nut is more convenient. The chain assembly shouldbe slipped into the mounting base so that the nylon nuts rest against the surface ofthe shaft (or coupling). Hold the chain out away from the base and slip the cylinderinto its cradle. To ensure maximum tightening range, each nut should be flushwith the end of the tightening bolt.
Place the base on the shaft (or coupling); a link of chain is slipped into the T-slot tosecure the base to the shaft. The soft-mount base does not have a chain pickup likethe B821007 Carbon Steel Mounting Base. After slipping a chain link into the T-slot, tighten the bolt at the end of the chain. Each mounting base can be installedon either end and the chain bolts placed on either side of the shaft. Take up anyslack in the chain using the chain clip (if necessary) and mount the laser fixtures to
the posts as described in the section Attaching the B821007 Carbon SteelMounting Base on page 2-19. The following photographs show the base mountedto a shaft. Grasping the bracket (not the laser fixtures) rotate the soft-mount basearound the shaft (or coupling).
Caution!
Grasping the laser fixtures could result in less accurate, unrepeatable data. This
is especially important when using the Dual Pass method where the data is auto-matically acquired as one fixture passes by the other.
Caution!
Coupling run-out will severely affect the accuracy of the soft mount brackets.Coupling run-out should be measured and subtracted from the reading during
use.
Caution!
To ensure measurement accuracy, the contact surfaces of the shaft (or coupling)must be free of dirt, grease, oil, etc. If cleaning is needed, Emerson recommends
thatyouuseasolvent-base cleaner Shaftkeys shouldbeavoided to reduce errors
8/6/2019 Laser Alignment 97191
74/394
2-54 Setting Up and Using Laser Alignment Fixtures
that you use a solvent-base cleaner. Shaft keys should be avoided to reduce errorsin accuracy.
9
Attaching the A8AA54 Narrow Mounting Base
The A8AA54, 1/2 inch (13mm) wide, narrow bracket was developed for smallmachines with shaft diameters of 4 - 1/2 inches (114 mm) and below, where theshaft can be rotated freely. Top and bottom v-shaped bars clamp snugly around the
shaft All isheldin placebyanyoneofthreefasteners:wingnutsforeasytightening
8/6/2019 Laser Alignment 97191
75/394
2-55Using Alternative Mounting Brackets
shaft. All is held in place by any one of three fasteners: wing nuts for easy tightening,hexagonal nuts for easy tightening in close quarters or a 1/2 inch (13mm) cou-pling nut for especially tight spaces. The bolts are hinged and can swing freely. Acotter pin can be inserted into the bracket to prevent the bolt from swinging.
10
Place the top v-shaped bar section (base) of the bracket on the shaft and thebottom v-shaped bar section of the bracket on the shaft (on the opposite side of theshaft from where the top v-shaped bar section has been placed) to secure thebracket to the shaft. Ensure that the bolts are seated in the outer most slots of thebottom section. When the top and bottom v-shaped bar bracket sections and bolts
are in place, tighten the nut at the end of the bolt to clamp the bracket to the shaft.
Screw the mounting posts into each hole in the mounting base and tighten withthe supplied tightener (Phillips screwdriver) or with a 1/8 inch Allen wrench (notsupplied with kit). Mount the laser fixtures to the posts as described in Attachingthe B821007 Carbon Steel Mounting Base on page 2-19. The photograph shows
the base mounted to a shaft.
8/6/2019 Laser Alignment 97191
76/394
2-56 Setting Up and Using Laser Alignment Fixtures
11
Note
Extension blocks are not available for this bracket.
8/6/2019 Laser Alignment 97191
77/394
Screw the mounting posts into each hole in the mounting base and tighten withthe supplied tightener (Phillips screwdriver) or with a 1/8 inch Allen wrench (notsupplied with kit). Mount the laser fixtures to the posts as described in Attachingthe B821007 Carbon Steel Mounting Base on page 2-19. Once the posts are in
place, mount the laser fixtures to the posts. The photograph shows the baset d t h ft
8/6/2019 Laser Alignment 97191
78/394
2-58 Setting Up and Using Laser Alignment Fixtures
p p p g pmounted to a shaft.
13
Note
Extension chains and blocks are not available for this bracket.
8/6/2019 Laser Alignment 97191
79/394
Screw the mounting posts into each hole in the mounting base and tighten withthe supplied tightener (Phillips screwdriver) or with a 1/8 inch Allen wrench (notsupplied with kit). Mount the laser fixtures to the posts as described in Attachingthe B821007 Carbon Steel Mounting Base on page 2-19. Attach the base to the
inside or outside of the coupling, depending on the coupling design and whetheror not you are performing a coupled or uncoupled alignment The photograph
8/6/2019 Laser Alignment 97191
80/394
2-60 Setting Up and Using Laser Alignment Fixtures
or not you are performing a coupled or uncoupled alignment. The photographillustrates the base attached to the outside of a coupling.
15
8/6/2019 Laser Alignment 97191
81/394
Advanced and Basic Laser Align Applications
The laser alignment program is available as an advanced laser align program
(which includes the ability to perform Basic jobs), and as a basic laser align pro-gram (which can only perform basic alignment jobs).
8/6/2019 Laser Alignment 97191
82/394
3-2 Horizontal Alignment
gram (which can only perform basic alignment jobs).
Advanced Laser Align
If the Advanced Laser Align application is loaded in a 2130 analyzer, the programcan be launched from the 2130 analyzers Home screen by pressing the Adv LaserAlign soft key. When the advanced application is selected, you will have access to thefull functionality described throughout this manual. The ability to perform basiclaser align jobs is included in this program.
Basic Laser Align
If the Basic Laser Align application is loaded in a 2130 analyzer, the program canbe launched by pressing the Basic Laser Align soft key on the 2130 analyzer homepage. When the basic application is selected, you will have access to a subset of thefunctionality described throughout this manual. Refer to the Basic Mode sectionon page 3-12 for a detailed description of the functionality available in the BasicLaser Align application.
Main Screen
The main Laser Align Application screen (sometimes referred to as the Main
Menu) allows you to monitor progress throughout the alignment job. When a hor-izontal alignment job is active, the Main screen displays as illustrated below.
8/6/2019 Laser Alignment 97191
83/394
3-3Main Screen
g j , p y
Laser Align Application Main screen at job start
The application defaults to a predefined setup when a new job is created. The typeof job, Job ID, Equipment ID, alignment method, number of machine moves, andnumber of notes attached to the job are displayed in the upper portion of the mainscreen.
Note
Unless otherwise noted, any defaults listed are displayed only at first.Once a field is modified from the default, the program uses the latestentry for that field.
The steps required to perform an alignment are displayed in the center portion ofthe main screen. The 2130 Laser Align program leads you through each step of aroutine alignment procedure starting with the Enter Dimensions selection at theMain screen. Once an alignment job has started the next uncompleted step in the
recommended procedure is highlighted.An [X] signifies a completed step As you complete steps the next recommended
8/6/2019 Laser Alignment 97191
84/394
3-4 Horizontal Alignment
An [X] signifies a completed step. As you complete steps, the next recommendedstep is highlighted. Initially, the Move Machine step is displayed, but grayed outuntil youve completed first two required steps which are critical to the alignmentjobs.
Up and Down Arrow keys
Use the Up and Down Arrow keys to highlight each feature. If you select an inactivestep, a popup message reminds you that the selected step is inactive due to missinginformation.
Three Step Alignment
To simulate the basic steps required to complete a horizontal alignment job, the
2130 Laser Align main screen is set up to allow an alignment job to be performedusing the following three steps:
8/6/2019 Laser Alignment 97191
85/394
3-5Three Step Alignment
1. enter dimensions,
enter machine dimensions
if thermal growth is enabled, enter thermal growth information; otherwise,this step is skipped
2. sweep laser heads,
if foot pre-check is enabled, perform Soft Foot or FDI check; otherwise, thisstep is skipped
acquire alignment data to determine the alignment condition of themachine
3. move machine review vertical moves
review horizontal moves
perform a live move (optional) and move the machine.
Main Screen Function Keys
Enter Dimensions
Use the Enter Dimensions key to advance to the Edit Dimensions screen where thedimensions for the machine being aligned can be entered. This is the first step of
8/6/2019 Laser Alignment 97191
86/394
3-6 Horizontal Alignment
g g pthe three-key operation used in performing an alignment job. If thermal growth isenabled, thermal growth information can also be entered from under this step.Refer to the Enter Dimensions section on page 3-45 for more information.
Sweep Laser Heads
Use the Sweep Laser Heads key to advance to the data acquisition screen for thealignment method defined for the job. This is the second step of the three-keyoperation used in performing an alignment job. From this screen alignment dataneeded to determine the alignment condition of the machine is acquired. If fo