HAMAR LASER STEALTH Series Installation guide

Table of Contents
An Introduction to Laser Alignment............................................................................................................. 1
Alignment System Components ................................................................................................................... 2
Lasers ........................................................................................................................................................ 2
The L-743 Ultra-Precision Triple Scan®Laser................................................................................ 2
The L-733 Precision Triple Scan® Laser ........................................................................................ 4
The L-742 Dual Scan® Ultra-Precision Roll Alignment Laser....................................................... 5
The L-732 Dual Scan® Precision Roll Alignment Laser ................................................................ 6
The L-730 Precision Leveling Laser................................................................................................ 7
The L-740 Ultra-Precision Leveling Laser ...................................................................................... 7
The L-741 Ultra-Precision Leveling Laser with Plumb Beam ........................................................ 8
Targets....................................................................................................................................................... 9
A-1519-2.4ZB and A-1520-2.4ZB Single-Axis Wireless Targets................................................... 9
Readouts.................................................................................................................................................. 10
The R-1357-2.4ZB Wireless, Ruggedized PDA Data Receiver with Read16 Android Software . 10
The R-1356-2.4ZB Wireless, Ruggedized PDA Readout with Read15 Software ......................... 11
The R-1307W Readout .................................................................................................................. 12
Computer Interface ................................................................................................................................. 13
A-910-2.4ZB Wireless Computer Interface................................................................................... 13
Preparing to Perform an Alignment............................................................................................................ 14
Defining Flatness and Level ................................................................................................................... 14
Setting Up the Targets............................................................................................................................. 14
Using the Control Panel .......................................................................................................................... 15
The Precision Level Vials ........................................................................................................................... 16
Reading the Precision Level Vials .......................................................................................................... 16
Reading the L-740SP Split-Prism Level Vials........................................................................................ 16
Calibrating the Level Vials ..................................................................................................................... 17
Zeroing the Targets........................................................................................................................ 17
Calculating the Calibration of the Level Vials – Roll Axis ........................................................... 18
Setting the First Level Vial – Roll Axis......................................................................................... 20
Checking the Levels for Accuracy................................................................................................. 20
Calculating the Calibration of the Levels Vials – Pitch Axis ........................................................ 21
Setting the First Level Vial – Pitch Axis ....................................................................................... 22
Checking the Levels for Accuracy................................................................................................. 22
Laser Buck-in.............................................................................................................................................. 23
Normal versus Remote Buck-In.............................................................................................................. 23
Normal Buck-In ............................................................................................................................. 23
Remote Buck-In ............................................................................................................................. 24
Three-Point Buck-In (Flatness)............................................................................................................... 25
3-Point Buck-In Procedure Using One Target............................................................................... 26
Setting up the Equipment............................................................................................................... 26
Performing the 3-Point Buck-In Using One Target ....................................................................... 26
3-Point Buck-In Procedure Using Multiple Targets ...................................................................... 27
2-Point Buck-In on Machine Tool Axis (Straightness)........................................................................... 28
Aligning the Laser to the X-Axis Travel ....................................................................................... 28
Measuring a Machining Center................................................................................................................... 30
Setting Up (Bucking-in) the Laser .......................................................................................................... 30
Procedure ....................................................................................................................................... 31
Aligning the Laser to the X-Axis Travel................................................................................................. 33

Measuring X-Axis Straightness and Flatness Simultaneously................................................................ 34
Y-Axis Flatness and Straightness and Y-Z / Y-X Squareness ............................................................... 35
W-Axis Flatness and Straightness, W-Z (in X) Parallelism, W-Z (in Y) Parallelism ............................ 37
Z-Axis Flatness and Straightness, Z-X and Z-Y Squareness, Z-W (in X) Parallelism, Z-W (in Y)
Parallelism............................................................................................................................................... 39
Additional Capabilities of the L-743 Machine Tool Alignment System ................................................ 41
Measuring Rotary Axes .............................................................................................................................. 41
Checking A and B Rotary Axes and Tramming the Spindle .................................................................. 42
Checking the B-Axis Flatness of Rotation, B-Z (in Y) Parallelism and B-X (in Y) Parallelism... 42
Checking the A-Axis Flatness of Rotation, A-X (in Z) Parallelism and A-Y (in Z) Parallelism .. 44
Tramming the Spindle.................................................................................................................... 46
Measuring Sawmills.................................................................................................................................... 47
Checking Log Carriage Straightness and Flatness/Level........................................................................ 47
Checking Support Rollers for Squareness............................................................................................... 48
Checking Saw-Blade Squareness............................................................................................................ 49
Checking Saw-Blade Parallelism............................................................................................................ 50
Checking Plumbness of Blades............................................................................................................... 50
Roll Alignment Buck-in and Laser Transfer Procedure ............................................................................. 51
The L-742 Alignment Procedure ............................................................................................................ 52
Horizontal Roll Parallelism............................................................................................................ 52
Choosing a Reference for Roll Alignment..................................................................................... 52
Remote Buck-in Formula............................................................................................................... 58
Using Read15 for Remote Buck-Ins on Rolls......................................................................................... 59
Leveling Rolls................................................................................................................................ 61
Arc Measurement Method - Sweeping Through the Arc............................................................... 62
Tramming Method for Hard-to-Reach Rolls ................................................................................. 63
The T-1600 Non-Magnetic Roll Fixture for the A-1519-2.4ZB Targets ................................................ 64
TDC Procedure .............................................................................................................................. 64
Checking Drive Shaft Alignment............................................................................................................ 64
Appendix A – Equipment Drawings........................................................................................................... 65
Appendix C – Care and Cleaning of Target Optics .................................................................................... 75
Appendix D – Coping with Atmospheric Effects ....................................................................................... 76
Reducing Atmospheric Effects with Fans...................................................................................... 77
Electronic Damping ....................................................................................................................... 77
Air Turbulence and Outdoor Use - Fixed Centerline Alignment................................................... 78
Appendix E – Interpreting the A-1519/1520 Calibration Reports .............................................................. 79
Appendix F – Troubleshooting Guide ........................................................................................................ 81
Appendix G – The A-910 Radio Transceiver/Hub and the A-910-2.4ZB Radio ....................................... 84
Front Panel Features ...................................................................................................................... 84
Rear Panel Features........................................................................................................................ 84
The Zigbee®Radio Utility for the A-910-24.ZB .................................................................................... 85
Pre-installing the Common USB Port Driver (A-910-2.4ZB) ....................................................... 85
Installing the A-910 Utility Software ............................................................................................ 85
Configuring the Hardware and Utility Settings ............................................................................. 86
Manually Selecting the COM Port................................................................................................. 87
Setting the Target System ID and Target Network ID................................................................... 88
Setting the System ID .................................................................................................................... 88
Appendix H – Centering the Targets on the Floor Monuments.................................................................. 89

Appendix I – Using Older Alignment Systems .......................................................................................... 91
Lasers ...................................................................................................................................................... 91
Targets..................................................................................................................................................... 91
Target Cell Function and Accuracy ............................................................................................... 93
Readouts.................................................................................................................................................. 94
Target Connections for Scanning Lasers ....................................................................................... 95
Calibration of Readouts to Targets ......................................................................................................... 95
Appendix J – Machine Tool Alignment Methods for Older Equipment................................................... 101
Level to Earth Measurements ............................................................................................................... 101
Setting Up and Leveling the Laser............................................................................................... 101
Three-Point Buck-In (Flatness)............................................................................................................. 101
Three-Point Buck-In Procedure Using One Target...................................................................... 102
Three-Point Buck-In Procedure Using Multiple Targets ............................................................. 104
Two-Point Buck-In (Straightness) ........................................................................................................ 104
Two Point Buck-In Procedure ..................................................................................................... 104
Close versus Remote Buck-In...................................................................................................... 105
Appendix K– Agency Certifications......................................................................................................... 108

1
An Introduction to Laser Alignment
Laser alignment is a simple and extremely accurate method of aligning machinery. A laser alignment
system consists of a laser, a target (or targets), and some form of readout (either a hand-held device or a
computer interface). The laser provides an intense, narrow beam of light that stays focused over distances
of up to 100 ft. The target is a light sensitive cell that can detect the absolute center of the laser beam.
When the target is placed in the line of the laser beam, the readout displays the offset between the center
of the laser beam and the center of the target cell, either graphically, numerically, or both.
In addition to lasers that produce a straight beam of light, Hamar Laser also manufactures laser that
produce a continuously sweeping plane. These planes are produced by bending a laser beam precisely 90°
using an optical penta prism. A laser plane is used for alignment by making it parallel (or “bucked-in”) to
three reference points or a datum plane, and then using targets to measure deviations from those points.
Once the laser is bucked in, any point within range of the laser system (up to a 100 ft. radius (30.5 m))
can be aligned to the reference points.
Hamar Laser’s multi-plane lasers, such as the L-733 and L-743, generate up to three ultra-flat laser planes
(both horizontal and vertical) and can be used with multiple targets on multiple axes to check alignment.
In most cases, this requires only one setup procedure.
Laser “buck-in” refers to the adjustment of a laser plane or line to be parallel to the surface being
measured (a tabletop, a surface plate, or a way surface). Three points are required to buck-in a laser plane
to a reference surface. Two points are needed to buck-in a straight-line laser to a reference line (i.e.,
centerline). For most machining centers, the alignment process begins by bucking-in the laser to five
reference points, three points using the horizontal laser plane (usually on the machine’s table) and two
using one of the vertical planes. The two reference points for the vertical plane are usually chosen from
either the X or Y straightness motion of the machine. The horizontal plane is measured using vertically
mounted targets and the vertical plane uses horizontally mounted targets. The pitch, roll and yaw of the
laser planes are adjusted by using adjustment knobs built into the base of the laser.
After bucking in, the target is moved to various points along the surface where it measures deviation from
the laser reference plane. For squareness, a target is placed (usually horizontally) on one part of the
column and zeroed. The column is then traversed up or down and any deviation becomes a measurement
of squareness since the laser plane used for measuring is perpendicular to the reference laser plane.
This manual will cover the four procedures that are necessary to use a Hamar Laser alignment system:
1. Reading and Calibrating the Laser’s Precision Level vials
2. Three-Point Buck-In
3. Two-Point Buck-In
4. The NORMIN Procedure
Any alignment you perform consists of one or more of these procedures. This manual will explain these
procedures and how to perform them. By fully understanding them, you will be able to align virtually any
machine, transfer line or production setup. In addition, this manual contains several appendices that cover
more advanced procedures and alignments using older Hamar Laser products.

2
Alignment System Components
Lasers
The L-743 Ultra-Precision Triple Scan®Laser
The L-743 Ultra-Precision Triple Scan®Laser is Hamar Laser’s most
versatile and powerful machine tool alignment laser. It has been
designed specifically for 3-5-axis machining centers to measure and
correct machine geometry. In most cases, all it takes is one setup to
measure flatness, straightness, parallelism and squareness of the main
axes of most typical machining centers.
Since the system provides live measurements, any errors that are
found can be fixed with the same setup. The laser mounts on a
machine or stable base so that the laser plane can project the
measurement reference out to 100 ft. (30.5 m) in radius for each laser
plane.
Applications: (for alignments with tolerances of .00002 in/ft or 0.0017 mm/m or greater)
•
Machining centers (HBMs, VBMs, HMCs, VMCs,
VTLs, gantries and surface grinders)
•
Automotive transfer-line wing bases
•
Injection molding machines and presses
•Aircraft assembly (seat track alignment, setting water, butt and station planes, wing-to-body and body-
to-body join alignment, etc.)
Roll parallelism in:
•High-precision, laser and water-jet cutting machines
•Paper mills
•Film lines
•Circuit board drilling machines
•Printing presses
•Blown-film lines
Measuring and aligning:
•The flatness of almost any surface (squares, frames,
ways, flanges, circles, etc.)
•The squareness of up to 3 surfaces
•Measuring surfaces up to 200 ft. (61 m) long with
one setup
•The parallelism of horizontal and vertical surfaces up
to 100 ft. (30.5 m) apart
•Checking way twist and parallelism between
horizontal surfaces
•The straightness of horizontal and vertical
surfaces
•The straightness and flatness of
horizontally and vertically traversing axes
•Checking plumb of a vertical surface up to
100 ft. (30.5 m)
•Checking way twist and parallelism
between vertical surfaces
Warning!
Always operate the L-730 and L-740 series lasers described below in an upright position.
Do NOT invert!

3
Features
•3 continuously rotating laser planes with operational
range of 100 ft. (30.5 m) in radius.
•Instant on with virtually no warm-up
•Top-to-Back and Top-to-Side Laser Planes are square
to 1 arc sec (.00006 in/ft or 0.005mm/m).
•Side-to-Back Laser Planes are square to 3 arc sec
(.00018 in/ft or 0.015mm/m).
•Standard levels are accurate to 2 arc second (.00012
in/ft or 0.01 mm/m).
•Split-Prism Upgrade Levels are accurate to 1 arc
second (.00006 in/ft or 0.005 mm/m).
•Targets provide live data display
•Standard target: A-1519-2.4ZB Single-Axis Wireless
Target with 0.5 micron (.000002 in.) resolution
•Uses A-1520-2.4ZB Single-Axis Wireless Target
with 0.25 micron (.000001 in.) resolution for higher
accuracy applications.
•Laser and targets fit into a small, portable shipping
case
•M-124-LiPo 9V Lithium Polymer Rechargeable
Battery Pack or 110-240V A/C 9V Adapter
•Laser planes flat to ½ arc seconds (.00003
in/ft or 0.0025mm/m) in 180º sweep and ¼
arc second (.000015 in/ft or 0.0008mm/m)
in 90º sweep).
•Includes Pitch/Roll/Yaw base with coarse
and fine adjustments and lighted levels.
•System uses Windows-based software for
quickly recording and analyzing machine
geometry data
•Typical setup time 20 minutes or less

4
The L-733 Precision Triple Scan® Laser
The L-733 Triple Scan Laser was specifically designed for
machining centers to measure and correct machine geometry. It has
all of the innovative and highly useful features of the L-743 Ultra-
Precision Triple Scan Laser, with lower accuracy and a medium
adjustment base. It is very useful for checking the alignment of
large fabrications or aligning large airplane sections in aircraft
manufacturing.
In most cases, all it takes is one setup to measure flatness,
straightness, parallelism and squareness. Since the system provides
live measurements, any errors that are found can be fixed with the
same setup. The laser mounts on a machine or stable base so that
the laser plane can project the measurement reference out to 100 ft.
(33 m) in radius for each laser plane.
Applications: (for alignments with tolerances of .0005 in/ft or (0.038 mm/m) or greater)
•Machining centers (HBM, VBM, VTL, VMC,
HMC, gantries, surface grinders)
•Water jet and laser cutting machines
•
Leveling machine beds and ways
•Checking the alignment of large bearing surfaces
and fabrications
•Roll alignment (rubber, steel, textile and lower
accuracy film lines)
•Aircraft assembly (seat track alignment, setting
water, butt and station planes, wing-to-body and
body-to-body join alignment, etc.)
•Sawmills
•Vertical press alignment
Measuring and aligning:
•
The flatness of almost any horizontal or vertical
surface (squares, frames, ways, flanges, circles,
etc.) or axes
•The squareness of any 2 vertical surfaces or axes
•
The straightness of vertical and horizontal
axes
•Measuring surfaces up to 200 ft. (66 m) long
with one setup
•Way twist and parallelism between vertical or
horizontal surfaces
•The parallelism of vertical or horizontal
surfaces up to 100 ft. (33 m) apart
•Way twist and parallelism between vertical or
horizontal surfaces
•The squareness of any vertical machine axis or
surface to horizontal axis or surface
•Checking plumb of a vertical surface up to 100 ft.
(33 m)
Features:
•Continuously rotating laser planes with
operational range of 100 ft. (33 m) in radius.
•Top-to-Back and Top-to-Side Laser Planes are
square to 2 arc sec (.00012 in/ft or 0.01mm/m).
•Standard target: A-1519-2.4ZB Single-Axis
Wireless Target with 0.5 micron (.000002 in.)
resolution
•System uses Windows-
based software for
quickly recording and analyzing machine
geometry data
•Typical setup time 20 minutes or less
•Laser planes flat to 2 arc seconds in 180º sweep
and 1 arc-second in 90º sweep.
•Side-to-Back Laser Planes are square to 3 arc
sec (.00018 in/ft or 0.015mm/m).
•Includes Pitch/Roll/Yaw base with medium-
resolution adjustments and lighted levels. Levels
accurate to 2 arc seconds.
•M-124-LiPo 9V Lithium Polymer
Rechargeable Battery Pack or 110-240V A/C
9V Adapter

5
The L-742 Dual Scan® Ultra-Precision Roll Alignment Laser
With two continuously sweeping, ultra-flat, orthogonal laser
planes, the L-742 Dual Scan®Laser is ideally suited to roll
alignment applications. The laser can be configured at the factory
to have either 2 vertical planes (typically used for roll alignment),
or 1 horizontal and 1 vertical plane, allowing a user to not only
measure, but also fix alignment problems in a fraction of the time
needed with conventional methods.
Using the L-742 you can quickly and easily check and correct
horizontal roll parallelism of even the tallest process mills, pick
up and check offset centerline benchmarks, and perform similar
alignments with increased accuracy and shorter setup times.
Applications: (for alignments with tolerances of .00002 in/ft or 0.0017 mm/m or higher)
•Roll parallelism in paper mills, printing presses
and film lines
•Leveling almost any surface (squares, frames,
ways, flanges, circles, etc.
•Roll forming machines
•High-precision, laser and water-
jet cutting
machines
•Measuring surfaces up to 200 ft. (61 m) long with
one setup
•Checking plumb of a vertical surface up to 100
ft. (30.5 m)
•Checking way twist and par
allelism between
surfaces
•Circuit board drilling machines
Measuring and aligning:
•The flatness and straightness of almost any surface
(squares, frames, ways, flanges, circles, etc.)
•The flatness and straightness of horizontally
and vertically traversing axes
•The parallelism of vertical or horizontal surfaces,
even if those surfaces are 100 ft. (30.5 m) apart
•The squareness of any 2 surfaces
•
The flatness and straightness of vertical
surfaces
Features
•Continuously rotating laser planes with
operational range of 100 ft. (33 m) in radius.
•Laser planes flat to 0.5 arc seconds in 180º sweep
and 0.25 arc-second in 90º sweep.
•Standard target: A-1519-2.4ZB Single-Axis
Wireless Target with 0.5 micron (.000002 in.)
resolution
•Standard levels are accurate to 2
arc second
(.00012 in/ft or 0.01 mm/m).
•Split-Prism Upgrade Levels are accurate to 1 arc
second (.00006 in/ft or 0.005 mm/m).
•System uses Windows-
based software for
quickly recording and analyzing machine
geometry data
•Typical setup time 20 minutes or less
•Top-to-Back Laser Planes are square to 1 arc sec
(.00006 in/ft or 0.005 mm/m).
•Side-to-Back Laser Planes are square to 3 arc sec
(.00018 in/ft or 0.015mm/m).
•Includes Pitch/Roll/Yaw base with
fine and
medium-resolution adjustments and lighted levels.
•M-124-LiPo 9V Lithium Polymer Rechargeable
Battery Pack or 110-240V A/C 9V Adapter

6
The L-732 Dual Scan® Precision Roll Alignment Laser
Primarily designed for roll alignment and other similar
alignment applications that do not require the exacting
tolerances of the L-742 Ultra-Precision Dual Scan®Laser,
the L-732 Precision Dual Scan®Laser also offers 2
automatically rotating laser planes that can be configured at
the factory to have either 2 vertical planes (typically used for
roll alignment), or 1 horizontal and 1 vertical laser plane.
Using the L-732 you can quickly and easily check and
correct horizontal roll parallelism of even the tallest process
mills, pick up and check offset centerline benchmarks, and
perform similar alignments with increased accuracy and
shorter setup times.
Applications: (for alignments with tolerances of .00015 in/ft or (0.01 mm/m) or greater
•Normal or blown-film lines (roll alignment)
•Rubber (roll alignment)
•Leveling almost any surface (squares, frames,
ways, flanges, circles, etc.
•Laser cutting machines
•
Water-jet cutting machines
•Checking plumb of a vertical surface up to 100
ft. (30.5 m)
•Steel (roll alignment)
•Sawmills
•Checking way twist and parallelism between
vertical surfaces
•Textiles (roll alignment)
Measuring and aligning:
•The flatness of almost any vertical surface
(squares, frames, ways, flanges, circles, etc.)
•The straightness of horizontally and vertically
traversing axes
•The parallelism of vertical or horizontal surfaces,
even if those surfaces are 100 ft. (30.5 m) apart
•Measuring surfaces up to 200 ft. (61 m) long with
one setup
•The squareness of any two vertical surfaces
•
The flatness and straightness of vertical
surfaces
Features
•Continuously rotating laser planes with
operational range of 100 ft. (33 m) in radius.
•Laser planes flat to 2.0 arc seconds in 180º
sweep and 1.0 arc-second in 90º sweep.
•Standard target: A-1519-2.4ZB Single-Axis Wireless
Target with 0.5 micron (.000002 in.) resolution
•Standard levels are accurate to 2 arc second (.00012
in/ft or 0.01 mm/m).
•Split-
Prism Upgrade Levels are accurate to 1 arc
second (.00006 in/ft or 0.005 mm/m).
•System uses Windows-
based software for quickly
recording and analyzing machine geometry data
•Typical setup time 20 minutes or less
•Top-to-Back Laser Planes are square to 2 arc sec
(.00012 in/ft or 0.01mm/m).
•Side-to-Back Laser Planes are square to 3 arc
sec (.00018 in/ft or 0.015mm/m).
•Includes Pitch/Roll/Yaw base with fine and
medium-resolution adjustments and lighted
levels.
•M-124-LiPo 9V Lithium Polymer Rechargeable
Battery Pack or 110-240V A/C 9V Adapter