PRÜFTECHNIK OPTALIGN smart RS5 BT Instruction Manual

1
A user’s handbook
Dear Customer,
Welcome to precision laser shaft alignment using OPTALIGN®smart RS5 BT. This
OPTALIGN smart RS5 BT handbook sets out to help the user work through the meas-
urement system with the required ease. It is meant to be a quick learning tool that
hopefully should make compelling reading.
PRÜFTECHNIK
85737 Ismaning
Germany
Email [email protected]
www.pruftechnik.com
Edition March 2016
Part number DOC 12.206.en
Firmware version 3.xx
OPTALIGN®smart RS5 is a registered trademark of PRÜFTECHNIK Dieter Busch AG.
PRÜFTECHNIK products are the subject of patents granted and pending throughout
the world. Contents subject to change without further notice, particularly in the
interest of further technical development. Reproduction, in any form whatsoever, only
upon express written consent of PRÜFTECHNIK.
© Copyright 2016 by PRÜFTECHNIK

OPTALIGN smart RS5 BT handbook
2
Foreword
OPTALIGN smart RS5 BT is a precision shaft alignment system that combines the
proven OPTALIGN smart computer with the technical capabilities of a new and
faster 5-axis technology sensor with integrated Bluetooth. This powerful wireless
communication laser alignment system is used in most industrial environments. The
computer with its ergonomic design and intuitive operation is user-friendly. It features
an alphanumeric keyboard with strategically placed navigation keys that handles all
data entry functions. The computer has a high resolution backlit colour TFT screen,
handy on-screen context menu, computer LEDs that give the instant status of the
alignment condition and a remarkable file storage capacity.
The RS5 BT sensor contains two XL HD position sensitive detectors (PSD) and incor-
porates Micro Electro Mechanical Systems (MEMS), making it possible to monitor live,
horizontal and vertical machine corrections concurrently, and with the sensor at any
shaft rotational position. During shaft rotation, in Continuous Sweep, more and finer
readings are taken faster. This ensures highly repeatable results even under mechani-
cal constraints such as backlash.
OPTALIGN smart RS5 BT possesses powerful features that include among others, user-
definable stationary feet, plain bearing machines, horizontal bolt-flanged machines,
various coupling types, wide selection of measurement modes to handle different
restrictions, thermal growth entry in terms of “target” coupling misalignment or
thermal growth amounts expected at machine feet, pipe strain and quick check
measurement.
The ‘OPTIONAL’ icon is used in this handbook to highlight all optional system features
and items.
If you have any suggestions for improvement or corrections (not just to this manual,
but also for hardware), please drop us a line (www.pruftechnik.com). We would be
glad to make improvements wherever possible.
We look forward to hearing from you.
PRÜFTECHNIK Condition Monitoring
March 2016
Ismaning, Germany

3
Contents
Contents
Foreword ..............................................................2
Chapter 1: OPTALIGN smart RS5 BT packages .................................5
1.1 OPTALIGN smart RS5 BT package with rechargeable battery computer ALI 12.015-RS5R 5
1.2 OPTALIGN smart RS5 BT package ALI 12.015-RS5 ............................................................9
Chapter 2: Safety notes and operating information...........................11
2.1 Safety notes..................................................................................................................11
2.2 Operating information ..................................................................................................12
Chapter 3: OPTALIGN smart RS5 BT – Description .............................17
3.1 Description ................................................................................................................... 17
3.2 Computer power supply ...............................................................................................18
3.3 RS5 laser and RS5 BT sensor .........................................................................................20
3.4 Mini compact chain-type bracket ALI 2.118 .................................................................. 27
Chapter 4: Getting started ...............................................29
4.1 Set-up ..........................................................................................................................29
4.2 Set RS5 BT sensor as default .........................................................................................30
4.3 Enter dimensions ..........................................................................................................31
4.4 Wireless measurement..................................................................................................32
4.5 Results..........................................................................................................................35
4.6 Context menu items .....................................................................................................37
Chapter 5: Horizontal machine alignment...................................39
5.1 Preparing for the alignment procedure .........................................................................39
5.2 Check for soft foot .......................................................................................................40
5.3 Mount the brackets .....................................................................................................40
5.4 Mount laser and RS5 BT sensor ....................................................................................42
5.5 Switch the computer on and start application ............................................................... 44
5.6 Enter machine dimensions ............................................................................................44
5.7 Machine set-up.............................................................................................................47
5.8 Flipping machines .........................................................................................................67
5.9 Laser beam adjustment.................................................................................................69
5.10 Take measurements .................................................................................................... 74
5.11 Results........................................................................................................................76
5.12 Rotating machine view................................................................................................ 84
5.13 Align machine.............................................................................................................85
5.14 Saving data and printing.............................................................................................94
5.15 Quick check measurement..........................................................................................99
5.16 Soft foot...................................................................................................................101

OPTALIGN smart RS5 BT handbook
4
5.17 Checking and correcting soft foot conditions............................................................102
5.18 Checking pipe strain .................................................................................................108
Chapter 6: Alignment features ..........................................113
6.1 Measurement modes ..................................................................................................113
6.2 Distinct measurement features....................................................................................116
Chapter 7: Special alignment applications..................................123
7.1 Machine train alignment.............................................................................................123
7.2 Cardan drive machines................................................................................................ 133
7.3 Vertical and horizontal flanged machines .................................................................... 142
7.4 Measure .....................................................................................................................148
7.5 Results........................................................................................................................149
7.6 Machine alignment.....................................................................................................152
Chapter 8: Configuration and data management ............................155
8.1 Shortcut numbers .......................................................................................................155
8.2 Configuration ............................................................................................................. 155
Chapter 9: Appendix ...................................................175
9.1 Updating system to a newer firmware version.............................................................175
9.2 Sensor firmware update..............................................................................................180
9.3 Suggested shaft alignment tolerances.........................................................................185
9.4 OPTALIGN smart RS5 BT technical data ....................................................................... 187
Index ................................................................189

5
OPTALIGN smart RS5 BT packages
Chapter 1: OPTALIGN smart RS5 BT
packages
ALI 12.015-RS5R is the standard OPTALIGN smart RS5 BT package.
For details of other available OPTALIGN smart RS5 BT stand-alone and add-on
packages, please contact your local PRÜFTECHNIK sales representative.
All optional items and features are highlighted in this handbook using the
‘OPTIONAL’ icon.
1.1 OPTALIGN smart RS5 BT package with rechargeable
battery computer ALI 12.015-RS5R
ALI 12.805 OPTALIGN smart RS5 case
ALI 12.200 OPTALIGN smart computer including
OPTALIGN smart rechargeable battery
ALI 12.601
ALI 12.201 Computer stand

Note
OPTALIGN
®
smart RS
ALI 12.805 ALI 12.200 ALI 12.201
ALI 12.601
00012
ALI 12.601
1.00

OPTALIGN smart RS5 BT handbook
6
ALI 12.651-I OPTALIGN smart charger (universal)
ALI 3.901 RS5 BT sensor
ALI 3.910 RS5 laser
ALI 3.953 RS5 BT sensor charger (universal)
ALI 3.952 Micro USB cable (for charging sensor)
ALI 3.901
ALI 3.952
ALI 3.910
ALI 12.651-I
ALI 3.953

7
OPTALIGN smart RS5 BT packages
ALI 12.502-2 PC cable for OPTALIGN smart computer
ALI 12.503 USB cable for peripherals
ALI 17.451 USB memory stick with ARC 4.0 software
and product literature
ALI 2.118 Small chain-type bracket [Note that the
OPTALIGN smart RS5 package contains 2
no. ALI 2.118]
ALI 2.911 Lens cleaning cloth
ALI 3.589 Tape measure mm/inch
ALI 2.118
ALI 17.451
ALI 12.503 ALI 12.502-2
ALI 2.911 ALI 3.589

OPTALIGN smart RS5 BT handbook
8
ALI 12.701 OPTALIGN smart shaft
firmware certificate (not shown)
DOC 12.106.en OPTALIGN smart RS5 BT pocket guide
DOC 12.206.en OPTALIGN smart RS5 BT operating
handbook (this handbook)
DOC 12.601 OPTALIGN smart RS5 BT safety and
general information
DOC 12.905.en OPTALIGN smart RS5 product catalogue
ALI 9.516.DG RS5 BT sensor inspection certificate (not
shown)
DOC 12.106.en
DOC 12.601
DOC 12.905.en

9
OPTALIGN smart RS5 BT packages
Due to shipping regulations that restrict airlines from transporting Lithium based
batteries with a charge exceeding 30% of their rated capacity, OPTALIGN smart
computer using the rechargeable battery and the RS5 sensor with integrated
Bluetooth may arrive at destination with discharged batteries. Charge the com-
ponents with the respective AC power supply/charger.

Note
1.2 OPTALIGN smart RS5 BT package ALI 12.015-RS5
In this package, the OPTALIGN smart computer is powered using 6 ‘AA’ size alkaline
batteries contained in the battery housing ALI 12.600. The rest of the standard items
are the same as those in the package ALI 12.015-RS5R but without the OPTALIGN
smart rechargeable battery ALI 12.601 and the OPTALIGN smart charger ALI 12.651-I.
ALI 12.600 OPTALIGN smart RS battery housing
ALI 12.600
Baby LR14 C AM2
No 4014 1,5V
Baby LR14 C AM2
No 4014 1,5V
NichtinsFeuerwerfen!
Nichtwiederaufladbar.
Mayexplodeinfire!Notrechargeable.
Nepasjeteraufeu!nonrechargeable.
Baby LR14 C AM2
No 4014 1,5V
NichtinsFeuerwerfen!
Nichtwiederaufladbar.
Mayexplodeinfire!Notrechargeable.
Nepasjeteraufeu!nonrechargeable.
Baby LR14 C AM2
No 4014 1,5V
Baby LR14 C AM2
No 4014 1,5V
NichtinsFeuerwerfen!
Nichtwiederaufladbar.
Mayexplodeinfire!Notrechargeable.
Nepasjeteraufeu!nonrechargeable.
Baby LR14 C AM2
No 4014 1,5V

OPTALIGN smart RS5 BT handbook
10
Page intentionally left blank

11
Chapter 2: Safety notes and operating
information
2.1 Safety notes
OPTALIGN smart RS5 BT is to be used in industrial environments only for shaft
alignment. Care must be taken to ensure that the instrument is not subjected to
mechanical knocks. OPTALIGN smart RS5 BT must be operated only by properly trained
personnel. No liability will be assumed when components or operating procedures as
described in this manual are altered without permission of the manufacturer.
2.1.1 Safety symbols
The following symbols are used in this manual in order to draw the reader’s attention
to especially important text, such as that regarding possible sources of danger or
useful operating tips.
This symbol denotes general information and tips regarding operation of
OPTALIGN smart RS5 BT.
This symbol denotes information which must be followed in order to avoid
damage to equipment.
This symbol denotes information which must be followed in order to avoid
personal injury.
This laser safety warning symbol denotes laser radiation.
Numbers in red circles indicate the corresponding operating step described in
these instructions and must be performed exactly.
2.1.2 CE compliance and electromagnetic compatibility
OPTALIGN smart RS5 BT components fulfills the EC Guidelines for electric devices and
those relating to electromagnetic compatibility as indicated in the respective conform-
ity certificates. The certificates may be downloaded from the PRÜFTECHNIK website.
2.1.3 IP classification
The computer, sensor and laser comply with code IP65 (dust-tight and protected
against water jets.
HNote
a
CAUTION
s
WARNING
1
Safety notes

OPTALIGN smart RS5 BT handbook
12
2.1.4 Laser safety
OPTALIGN smart RS5 BT system uses the RS5 laser ALI 3.910. According to IEC 60825-
1:2007, RS5 laser is classified as a Class 2 laser product. The laser complies with 21
CFR 1040.10 and 1040.11 except for deviations pursuant to Laser Notice No. 50,
dated June 24, 2007. The laser operates at a wavelength of 630 – 680 nm and has a
maximum radiant power <1 mW. No maintenance is necessary to keep the product
compliant as outlined above.
Do not look directly into the laser beam at any time. (The natural blink
reaction of the human eye is normally sufficient to protect the eyes from
any dangers posed by looking at the laser beam briefly. But as natural blink
reaction may fail to occur, care should be taken to avoid staring into the
beam.)
Do not insert any optical devices into the beam path.
The LED on the front of the laser illuminates whenever the laser beam is
emitted.
CAUTION – Use of controls or adjustments or performance of procedures
other than those specified herein may result in hazardous radiation
exposure
2.2 Operating information
2.2.1 Temperature range
OPTALIGN smart RS5 BT and its related system components must be used at tempera-
tures between -10°C and 50°C (14°F to 122°F). Outside of this range, the specified
accuracy may not be maintained.
Store the system and its related components at temperatures between -20°C and
60°C (-4°F to 140°F).
2.2.2 Temperature effects and fluctuations
Powerful heat sources or steam located near the laser beam could influence the
accuracy of measurements as a result of beam deflection. In practice, however, this
effect occurs seldom at distances up to 1 m. If in doubt, the effect can be elimi-
nated by shielding the system from the heat/steam source during measurement and
adjustment.
As with all precision optical measurement devices, sudden fluctuations in tempera-
tures (e.g. resulting from sunlight), could result in erroneous measurements.
Allow adequate time for the system and its related components to reach the
ambient temperature.
s
WARNING
HNote

13
2.2.3 Incident light
Avoid exposing the system to strong, hot light such as direct sunlight.
2.2.4 Dust and water seals
The system computer, sensor and laser are water and contamination resistant to speci-
fication IP65. This specification requires that each component be able to withstand a
water jet spray from any direction (the components are NOT guaranteed to withstand
a full submersion). As with most water-resistant products, the resistance must be
periodically checked. This can be carried out during service and inspection of the
system which is recommended to be carried out every two years.
2.2.5 Interface connection
OPTALIGN smart computer is fitted with a single interface for mains supply and data
exchange with a PC/printer.
2.2.6 Notes regarding data storage
With any data processing software, data may be lost or altered under certain
circumstances. PRÜFTECHNIK strongly recommends that you keep a backup or
printed records of all important data.
PRÜFTECHNIK assumes no responsibility for data lost or altered as a result of
improper use, repairs, defects, battery replacement/failures or any other cause.
PRÜFTECHNIK assumes no responsibility, directly or indirectly, for financial losses
or claims from third parties resulting from the use of this product and any of its
functions, such as loss or alteration of stored data.
2.2.7 Disposal
Any waste electrical and electronic parts of the OPTALIGN smart RS5 BT system
including memory sticks must be disposed off in accordance with the WEEE
(Waste Electrical and Electronic Equipment) Directive. Such parts must be taken
to the nearest collection facility.
HNote
Operating considerations

OPTALIGN smart RS5 BT handbook
14
2.2.8 Component labelling
Labels used in communicating laser safety and other general information are to be
found on the system component housings affixed as shown below.
Located at the back of both
the RS5 BT sensor ALI 3.901
and the RS5 laser ALI 3.910
is the respective inspection
label (shown opposite in red
– note that the white arrow
points to the month when the
respective inspection is due.
The year is shown at the center
of the inspection label. In these
examples, both sensor and laser
are due inspection in February
2017.
The laser safety warning
label, the laser identi-
fication label and the
laser inspection label are
affixed to the back of the
RS5 laser ALI 3.910.
Type
S.No.
HWS
Date
of manufacture
PRÜFTECHNIK AG
85737 Ismaning
www.pruftechnik.com
Made in Germany
Check calibration
ALI 3.901
3910 0108
0.80
März 2016
17
The RS5 BT sensor iden-
tification label and the
sensor inspection label are
affixed to the back of the
sensor ALI 3.901.
DO NOT STARE INTO BEAM
AVOID EXPOSURE
LASER RADIATION
LASER LIGHT IS EMITTED FROM THIS APERTURE
CLASS 2 LASER PRODUCT
IEC 60825-1:2007
P<1mW, pulse<400µs, λ=630-680nm
Complies with 21 CFR 1040.10 and
1040.11 except for deviations pursuant
to Laser Notice No. 50, dated June 24, 2007
Type
S.No.
HWS
Date
of manufacture
PRÜFTECHNIK AG
85737 Ismaning
www.pruftechnik.com
Made in Germany
Check calibration
ALI 3.910
3910 0108
1.00
März 2016
17
The laser beam hazard
symbol label is affixed at
the front of the RS5 laser
head.

15
The OPTALIGN smart
computer identification
label is located at the
bottom of the computer.
This label is located at the
back of the OPTALIGN
smart computer battery
housing.
Type S.No.
Component labelling

OPTALIGN smart RS5 BT handbook
16
This page intentionally left blank

Introducing OPTALIGN smart RS5 BT
17
Chapter 3: OPTALIGN smart RS5 BT –
Description
3.1 Description
3.1.1 OPTALIGN smart computer keyboard at a glance
The computer possesses three function keys.
d— The ‘Dimensions’ key is used to initiate entry of machine dimensions.
m— The ‘Measurement’ key is used to start the measurement process.
k— The ‘Result’ key is used to call alignment results into the display.
ß— The ‘Up’ key is used to confirm entered values, and as a back/return
key, taking user to previously selected screen.
c— The ‘Clr’ (Clear) key is used to delete information entered inadvertently.
q— The ‘Menu’ key offers a choice of procedures for setting up the
computer and proceeding with different alignment situations.
hifg— The navigation keys are used to navigate through the
program steps.
e— The ‘On/Off/Enter’ key is used to perform four functions – switching
OPTALIGN smart computer on/off, and accessing any selected item or
confirming an action. To switch on/off, press and hold e, the ‘On/Off/Enter’
key briefly.’
1— The data entry keys are used to enter relevant machine data.
1. Alignment condition LEDs
2. USB port / Sensor socket /
Charger socket
3. Function keys [d, m, k]
4. Up / Clear / Menu keys
5. Navigation keys
6. On/Off/Enter key
7. Data entry keys
8. Wireless communication
indicator LED
9. Battery status LED
3 4 521
9 8
OPTALIGN
®
smart RS
6
7

OPTALIGN smart RS5 BT handbook
18
3.2 Computer power supply
The OPTALIGN smart computer ALI 12.200 is powered using six standard ‘AA’ size
alkaline batteries contained in the battery housing ALI 12.600.
The rechargeable battery OPTALIGN smart computer option is powered using a 7.4 V
2.5 Ah Lithium-ion rechargeable battery ALI 12.601 (optional), which is to be charged
only using the AC power supply/charger ALI 12.651-I. The battery can be charged
only inside the computer.
The batteries allow operation of up to 18 hours (25% active measurement, 25%
standby, 50% ‘sleep’ mode).
3.2.1 Replacing batteries
The rechargeable battery ALI 12.601 and the battery housing ALI 12.600 have
identical shapes and are therefore interchangeable. If batteries require removal, turn
over the computer taking care not to damage the display and the hard keys. Undo
the two quarter-turn screws by rotating them at least 90° (1/4 turn). With the screws
loosened, lift and pull out the rechargeable battery or the battery compartment
(depending on power supply source). The reverse procedure is used to reinstall the
rechargeable battery or the battery compartment.
Due to their similarity, the battery housing ALI 12.600 is removed and replaced in the
same manner as the rechargeable battery ALI 12.601.
00012
ALI 12.601
1.00
Lift housing or rechargea-
ble battery after undoing
the screws
Replace compartment or
rechargeable battery by
sliding it into the groove
appropriately 6 ‘AA‘ size batteries
Battery housing
ALI 12.600
Baby LR14 C AM2
No 4014 1,5V
Baby LR14 C AM2
No 4014 1,5V
Nicht ins Feuer werfen!
Nicht wiederauadbar.
May explode in re! Not rechargeable.
Ne pas jeter au feu! non rechargeable.
Baby LR14 C AM2
No 4014 1,5V
Nicht ins Feuer werfen!
Nicht wiederauadbar.
May explode in re! Not rechargeable.
Ne pas jeter au feu! non rechargeable.
Baby LR14 C AM2
No 4014 1,5V
Baby LR 14 C AM2
No 4014 1,5V
Nicht ins Feuer werfen!
Nicht wiederauadbar.
May explode in re! Not rechargeable.
Ne pas jeter au feu! non rechargeable.
Baby LR14 C AM2
No 4014 1,5V
Rechargeable battery
ALI 12.601

Introducing OPTALIGN smart RS5 BT
19
If you are using the standard ‘AA’ size batteries, it is recommended to replace all of
them together. Note the battery polarity when inserting them in the housing ALI
12.600.
Used batteries should be disposed of in an environmentally responsible manner
in accordance with applicable regulations!
If OPTALIGN smart computer is not in use for extended periods of time, a month
or more, the batteries should be removed from the unit.
3.2.2 Charging the battery
Connect the AC power supply/charger ALI 12.651-I to the computer interface
connection and to the mains supply.
Before charging, the rechargeable battery should be discharged as much as pos-
sible. To charge the battery from 0% to 100% capacity takes approximately 4
hours.
The computer’s battery status LED indicates the charging status of the battery. A
flashing red LED indicates that the battery is either defective or fully discharged. The
LED flashes green at initialization and during the charging process. A constantly lit
green LED denotes that the battery is fully charged.
3.2.3 Mounting and dismounting the universal adapter/charger plug
ALI 12.651-I
The universal OPTALIGN smart adapter/charger ALI 12.651-I comes with three different
regional plugs. The available plugs are for the Euro zone, the US and the UK. When
mounting or dismounting a plug, pay attention to the direction of the arrow on the
plug just above the pins, and the arrow on the latching nipple on the charger housing.
To dismount a plug, push the latching nipple in the forward direction [ 1] as indicated
by the arrow on it and hold, then push the plug to the right [ 2] as on the arrow on
the plug.
m
a
CAUTION
HNote
The direction arrow
on the plug has the
inscription ‘OPEN’ marked
above it.
1
2
Latching nipple

OPTALIGN smart RS5 BT handbook
20
To mount a plug, push the latching nipple in the forward direction [ 1] as indicated
by the arrow on it then slip the plug into the protruding prongs and slide it to the left
until it latches.
3.3 RS5 laser and RS5 BT sensor
3.3.1 RS5 laser ALI 3.910
The RS5 laser is switched on by pressing its On/Off push button switch. The “beam
active” indicator LED lights red steady then blinks green slowly. The laser is switched
off by pressing and holding down On/Off push button switch until the LED turns off.
The semiconductor laser diode emits a ray of red light (wavelength 630 – 680 nm)
which is visible where it strikes a surface. The beam is emitted with a diameter of ap-
proximately 5 mm (3/16”). The laser is classified with a Class 2 safety rating.
Do not stare into the laser beam!
The beam is adjusted during set-up by changing its vertical and horizontal angles with
thumbwheels so that the beam strikes the sensor lens straight on.
The RS5 laser is water and dust resistant. The internal optics and electronics are
internally sealed, preventing possible contamination.
The battery compartment is not watertight. If water enters this compartment,
open it and dry it out. The two AA size batteries should then be replaced.
3.3.2 Laser batteries
The RS5 laser is powered using two high energy AA size alkali-manganese 1.5 V
batteries. These provide a typical operating duration of 180 hours.
As the battery becomes depleted, the colour of the ‘laser active’ indicator LED
changes from green (full) to yellow (half full) to red (empty). When this occurs,
the batteries should be replaced.
If the laser is not in use for extended periods of time, a month or more, the bat-
tery should be removed from the unit.
The batteries are replaced by undoing the quarter-turn screw on the battery
compartment cover by rotating it by at least 90° (1/4 turn). With the screw loosened,
lift the cover, and then use the red strap to remove the batteries. Replace both
batteries at the same time.
s
WARNING
a
CAUTION
a
CAUTION