PRÜFTECHNIK ROTALIGN Ultra iS User manual

ROTALIGN Ultra iS
Operating handbook - Shaft alignment

1
A user’s handbook
Dear Customer,
Welcome to the world of intelligent shaft alignment using ROTALIGN Ultra iS Shaft,
another innovative product from PRÜFTECHNIK, the inventors of laser shaft alignment.
This handbook sets out to help the instrument user work through the instrument with
the required ease. It is the standard work for both the ‘Advanced Shaft’ and ‘Standard
Shaft’ versions, and meant to be a quick learning tool that hopefully should make
compelling reading.
PRÜFTECHNIK Alignment Systems GmbH
Freisinger Str. 34
85737 Ismaning
Germany
Tel [phone]
Fax [phone]
Email [email protected]
Edition April 2014
Part number DOC 40.200.en
Firmware version 3.xx
sensALIGN®and ROTALIGN®are registered trademarks 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 Alignment Systems GmbH.
© Copyright 2014 by PRÜFTECHNIK Alignment Systems GmbH

ROTALIGN Ultra iS Shaft handbook
2
oreword
ROTALIGN Ultra iS is industry’s first intelligent alignment system. The system combines
the features of the tested and proven ROTALIGN Ultra iS computer together with
those of the next generation sensALIGN sensor and laser. ROTALIGN Ultra iS computer
features a 5.7-inch (145 mm) colour TFT sunlight readable full VGA screen, a fast
processor, an alphanumeric keyboard with strategically placed navigation keys that
handles all data entry functions, a long lasting rechargeable battery, handy on-screen
context menu, a remarkable file storage capacity and computer LEDs that give the
instant status of the alignment condition and laser beam adjustment.
sensALIGN sensor possesses an unlimited detector range making it possible to measure
grossly misaligned machines or those with long couplings. Both sensor and laser
incorporate Micro Electro Mechanical System (MEMs) allowing the measurement of
component rotational angle and vibration. sensALIGN sensor incorporates Bluetooth
for wireless transmission of measurement data to the system computer. Both sensor
and laser are powered using Lithium Polymer (Li-Po) rechargeable batteries.
In its completeness, the system handles the alignment of drive trains comprising up to
14 machines and includes intelligent features such as ellipse calculation, monitoring
environmental vibration, live measurement quality and suppression of coupling
backlash.
If you have any suggestions for improvement or corrections (not just to this manual,
but also for hardware), please drop us a line. We would be glad to make improve-
ments wherever possible.
We look forward to hearing from you.
PRÜFTECHNIK Alignment Systems
Ismaning, Germany

Contents
3
Contents
oreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Chapter 1: ROTALIGN Ultra iS Shaft package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.1 ROTALIGN Ultra iS Shaft package ALI 40.000 ..................................................................5
Chapter 2: System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Safety notes .................................................................................................................11
2.2 Getting to know the ROTALIGN Ultra iS computer .......................................................14
2.3 sensALIGN laser ALI 4.910 ............................................................................................ 20
2.4 sensALIGN sensor ALI 4.900 ......................................................................................... 23
2.5 Handling precautions....................................................................................................25
Chapter 3: Getting started with the ROTALIGN Ultra iS Shaft system . . . . . . . . . . . .27
3.1 ROTALIGN Ultra iS Shaft system composition ................................................................27
3.2 Obtaining alignment readings in quick intelligent steps................................................. 27
3.3 Tips and tricks ..............................................................................................................32
Chapter 4: Shaft alignment application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.1 Starting the shaft alignment application ....................................................................... 35
4.2 Horizontal machine alignment – preparing for the alignment procedure .......................36
4.3 Check soft foot ............................................................................................................37
4.4 Mount the brackets ..................................................................................................... 37
4.5 Mount sensALIGN laser and sensor ..............................................................................39
4.6 Switch ROTALIGN Ultra iS on and start application ....................................................... 40
4.7 Enter machine dimensions ............................................................................................ 41
4.8 Machine properties ..................................................................................................... 42
4.9 Coupling properties .....................................................................................................47
4.10 Flipping machines ....................................................................................................... 52
4.11 Laser beam adjustment ..............................................................................................54
4.12 Taking measurements ................................................................................................. 56
4.12a Taking measurements using the sensALIGN sensor and laser cable ........................... 60
4.13 Results ...................................................................................................................... 61
4.14 Align machine ............................................................................................................67
4.15 Saving and printing measurement files........................................................................ 75
4.16 Alignment completion ............................................................................................... 82
Chapter 5: Alignment features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.1 Measurement modes .................................................................................................... 83
5.2 Measurement options ..................................................................................................97
5.3 Measuring vibration....................................................................................................118
5.4 Set-up options ............................................................................................................ 123
5.5 Soft foot ....................................................................................................................133

ROTALIGN Ultra iS Shaft handbook
4
Chapter 6: Special alignment applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
6.1 Machine train alignment ............................................................................................141
6.2 Cardan shaft alignment .............................................................................................. 147
6.3 Flanged machines ......................................................................................................155
6.4 Flange-mounted horizontal machines.......................................................................... 165
Chapter 7: Updating ROTALIGN Ultra firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
7.1 Updating ROTALIGN Ultra firmware to higher version..................................................171
Chapter 8: ROTALIGN Ultra iS Shaft configuration . . . . . . . . . . . . . . . . . . . . . . . . . .177
8.1 Configuration ............................................................................................................177
8.2 User accounts ............................................................................................................. 191
8.3 Creating templates ..................................................................................................... 198
8.4 Deleting created templates from the program manager .............................................. 200
8.5 Available applications and options ............................................................................. 202
8.6 Upgrading from Standard Shaft to Advanced Shaft version ......................................... 204
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Suggested shaft alignment tolerances............................................................................... 207
ROTALIGN Ultra iS technical data ......................................................................................209
sensALIGN sensor and laser ‘ON/OFF/CHARGE’ workflow.................................................. 211
Declaration of conformity ................................................................................................. 212
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

ROTALIGN Ultra iS Shaft package
5
Chapter 1: ROTALIGN Ultra iS Shaft package
ALI 40.000 is the ROTALIGN Ultra iS Advanced Shaft package.
For details of other available ROTALIGN Ultra iS stand-alone and add-on
packages, please contact your local PRÜFTECHNIK sales representative.
1.1 ROTALIGN Ultra iS Shaft package ALI 40.000
ALI 4.820 ROTALIGN Ultra iS Shaft case
ALI 4.202 ROTALIGN Ultra iS computer including:
ROTALIGN Ultra iS rechargeable battery
ALI 4.603
ROTALIGN Ultra iS stand ALI 4.201
ALI 4.910 sensALIGN laser [sensALIGN rechargeable
battery ALI 4.960 is mounted]
ALI 4.900 sensALIGN sensor [sensALIGN rechargeable
battery ALI 4.960 is mounted]
ALI 40.000-L is the
ROTALIGN Ultra iS
Standard Shaft package.
)
Note
For details of other available ROTALIGN Ultra iS stand-alone and add-on
packa
g
es, please contact
y
our local PR
Ü
FTECHNIK sales representative.
ALI 4.820
ALI 4.202
ALI 4.910 ALI 4.900
Align ent intelligent Syste

ROTALIGN Ultra iS Shaft handbook
6
ALI 4.921-2 sensALIGN sensor and laser cable
ALI 4.651-I sensALIGN charger/adapter (universal)
– for powering and charging sensALIGN
sensor/laser and rechargeable battery
ALI 12.502-2 PC/USB cable
ALI 12.503 USB/peripheral devices cable
ALI 12.651-I AC power supply/charger (universal) – for
powering and charging ROTALIGN Ultra iS
computer and rechargeable battery
ALI 4.921-2 ALI 4.651-I ALI 12.503
ALI 12.502-2 ALI 12.651-I
CAUTION: The universal
mains adapter is supplied
with plugs for the EU,
US and UK. Care must
exercised when changing
the plugs. Please refer
to the plug mounting
procedure in section 2.2.5.

ROTALIGN Ultra iS Shaft package
7
ALI 2.113 SET Compact chain-type bracket set
includes: chains — ALI 2.114, ALI 2.115,
support posts — ALI 2.170, ALI 2.171,
ALI 2.172, ALI 2.173, ALI 2.174 and storage
pouch — ALI 3.590-200
ALI 2.905 Lens cleaning cloth
ALI 3.588 Tape measure mm/inch
DOC 40.100.en ROTALIGN Ultra iS Shaft pocket guide
DOC 40.200.en ROTALIGN Ultra iS Shaft
operating instructions
DOC 40.900.en ROTALIGN Ultra product catalog
ALI 2.113 SET
ALI 2.905 ALI 3.588
DOC 40.200.en
DOC 40.100.en
DOC 40.900.en

ROTALIGN Ultra iS Shaft handbook
8
ALI 13.700 CD ALIGNMENT CENTER CD
ALI 4.741 ROTALIGN Ultra Advanced Shaft
irmware registration certificate
(not shown)
ALI 4.905 Vibration check probe
ALI 4.451 USB memory stick
0 0739 1055 Allen key (2.5 mm)
ALI 13.700 CD
ALI 4.451
0 0739 1055
ALI 4.905

ROTALIGN Ultra iS Shaft package
9
1.1.1 Optional ROTALIGN Ultra iS components
ALI 4.605 ROTALIGN Ultra iS disposable battery
housing
ALI 4.615 Desktop charging station for ROTALIGN
Ultra iS rechargeable battery
ALI 4.615 SET Desktop charging station set for
ROTALIGN Ultra iS rechargeable battery
includes:
Desktop charging station ALI 4.615
ROTALIGN Ultra iS rechargeable battery
ALI 4.603
ALI 4.410 Dust cap for computer sensor socket
ALI 4.615
ALI 4.605
ALI 4.410
ALI 4.603

ROTALIGN Ultra iS Shaft handbook
10
This page intentionally left blank

11
Chapter 2: System description
2.1 Safety notes
ROTALIGN Ultra iS is to be used in industrial environments only for alignment of
turbine components, shafts, bores, measurement of straightness and flatness of
different surfaces. It is dust proof and water resistant with a rating of IP 65. Although
shockproof, care must be taken to ensure that the instrument is not subjected to
mechanical knocks. ROTALIGN Ultra iS 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 Symbols used in this handbook
The following symbols are used in this manual in order to draw the reader’s attention
to especially important text, such as possible sources of danger or useful operating
tips.
This symbol denotes general information and tips regarding operation of
ROTALIGN Ultra iS.
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.
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
ROTALIGN Ultra iS fulfills the EC Guidelines for electric devices and those relating to
electromagnetic compatibility as indicated in the conformity certificate attached in the
appendix. The certificate may also be downloaded from the PRÜFTECHNIK website.
Note that the necessary
application firmware
[bore alignment,
flatness, straightness
among others] must be
purchased, installed and
licenced.
This s
y
mbol denotes
g
eneral information and tips re
g
ardin
g
operation of
ROTALIGN U
l
tra iS.
This symbol denotes in
f
ormation which must be
f
ollowed in order to avoid
dama
g
e to equipment.
This symbol denotes in
f
ormation which must be
f
ollowed in order to avoid
persona
l
in
j
ur
y.
Num
b
ers in re
d
circ
l
es in
d
icate t
h
e correspon
d
ing operating step
d
escri
b
e
d
in
these instructions and must be performed exactl
y.
Note

CAUTION

WARNING
1
Safety notes

ROTALIGN Ultra iS Shaft handbook
12
2.1.3 Laser safety
The ROTALIGN Ultra iS system uses sensALIGN laser ALI 4.910. According to IEC
60825-1, sensALIGN laser is classified as a Class 2 laser product. The laser operates
at 635 nm and has a maximum radiant power <1 mW. It complies with the FDA
specifications 21 CFR 1040.10 and 1040.11 except for deviations pursuant to laser
notice No. 50, dated June 24, 2007. No maintenance is necessary to keep this product
in compliance with the specifications referred to.
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 red LED on the front of sensALIGN 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.

WARNING
Do not look directl
y
into the laser beam at an
y
time. (The natural blink
reaction o
f
the human eye is normally su
ffi
cient to protect the eyes
f
rom
any dangers posed by looking at the laser beam brie
fl
y. But as natural blink
reaction ma
y
fail to occur, care should be taken to avoid starin
g
into the
beam.
)
Do not insert an
y
optical devices into the beam path.
Th
e
r
ed
LED
o
n
t
h
e
f
r
o
n
t
of
se
n
s
ALI
G
N l
ase
r ill
u
min
ates
wh
e
n
e
v
e
r
t
h
e
l
ase
r
beam is emitted.
CAUTION – Use o
f
controls or adjustments or per
f
ormance o
f
procedures
other than those specified herein ma
y
result in hazardous radiation
e
x
pos
u
re.

CAUTION

13
2.1.4 Component labelling
The labelling diagram below represents both sensALIGN sensor and sensALIGN laser.
The diagram shows the engraved symbols, markings and labels as they appear on the
respective measurement head. The laser safety labels are affixed on the housing of
sensALIGN laser at the positions shown in the diagram. The rechargeable battery label
is located on the rear of sensALIGN rechargeable battery.
Component labelling
Rechargeable lithiumpolymer battery
6Wh 3,7V 1,6Ah
Trange = -10°C/14°F to 50°C/120°F
Charge only with battery charger ALI 4.651-I
between 0°C/32°F to 40°C/104°F
Aufladen nur mit Ladegerät ALI 4.651-I
imBereich 0°C/ 32°F to 40°C/104°F
Caution
• Do not incinerate
• Do not disassemble
• Do not burn or expose to high temperature
• Do not short-circuit
• Dispose properly
Manufacturer:
PRÜFTECHNIK Alignment Systems GmbH
85737 Ismaning, Germany
www.pruftechnik.com
en ALIGN™
LASER RADIATION
CLASS 2 LASER PRODUCT
IEC 60825-1:2007
P < 1mW, pulse < 400µs λ=635nm
Complies with 21 CFR 1040.10
and 1040.11 except for deviations
pursuant to Laser Notice No. 50,
dated June 24, 2007
DO NOT STARE
INTO BEAM
U
N
L
I
M
I
T
E
D
P
R
E
C
I
S
I
O
N
s
e
n
s
A
L
I
G
N
T
M
L
a
s
e
r
OPEN
LASER RADIATION
DO NOT STARE INTO BEAM
P < 1mW, pulse < 400µs λ=635nm
CLASS II LASER PRODUCT
AVOID EXPOSURE-Laser radiation
is emitted fromthis aperture
C A U T I O N
1
12
11
10
9
8
7
6
5
4
3
2
16
The black label is on the back of
sensALIGN rechargeable battery
ALI 4.960 which is mounted on
both sensALIGN laser ALI 4.910
and sensALIGN sensor ALI 4.900.
This label is found on
the side of sensALIGN
laser ALI 4.910.
The part number,
serial number and
date of manufacture
are engraved at
the bottom of both
sensALIGN sensor and
laser. The service and
calibration label is also
attached at the bottom
of the units.
This circular label is located
on the outside of the
sensALIGN laser aperture.
This label is found
on the side of
sensALIGN laser
ALI 4.910.
This symbol is engraved on the
top of both sensALIGN laser
and sensor, and indicates the
direction of the clamping levers
open position.
This symbol is engraved on the side of sensALIGN
sensor next to the countersunk hole, and indicates the
position to place the vibration check probe ALI 4.905
In this example, the next
calibration due date is May
2016.

ROTALIGN Ultra iS Shaft handbook
14
2.2 Getting to know the ROTALIGN Ultra iS computer
The ROTALIGN Ultra iS computer has been developed to effectively handle both
simple and complex shaft, bore and turbine diaphragm applications. The computer is
also used to carry out straightness and flatness measurements. ROTALIGN Ultra iS has
a customer-oriented user interface. It uses easy-to-follow icons and comprehensive
on-screen menus and hint texts, that enable even first-time users to operate the
computer without difficulty.
The label opposite is on the back of ROTALIGN Ultra iS
computer, affixed to the rechargeable battery in current use.
The above label is affixed on the back of ROTALIGN Ultra iS
computer ALI 4.202.
USB port/Charger socket USB/Charger socket
Sensor socket
Up/Clear/
Menu keys
Bluetooth communication LED
Function keys
Battery status LED
Data entry keys
Laser adjustment and alignment
condition LEDs
Navigation keys
On/Off/Enter key

15
ROTALIGN Ultra iS is built to rugged industrial standards of shock and water resistance.
It contains a complete computer with a 5.7 inch (145 mm) color TFT full VGA display,
oval-shaped function and data entry keys, 4-way navigation keys, an On/Off/Enter
key, an up key, a clear key and a menu key.
2.2.1 Operating keys
The navigation keys are used to navigate through the menu and display items.
The ‘On/Off/Enter’ key is used to perform four functions – switching ROTALIGN
Ultra iS 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.
The ‘Up’ key is used as a back/return key, taking user to previously selected
function, or to exit current screen.
The ‘CLR’ (Clear) key is used to delete information entered inadvertently.
The ‘Menu’ key is used to call-up menu options related to the selected display
screen. Pressing it twice brings up the global menu.
The data entry keys are used to enter relevant data.
ROTALIGN Ultra iS possesses 3 function keys.
The ‘Dimension’ key is used to access machine set-up where machine
dimensions and properties are defined.
The ‘Measurement’ key is used to access the measurement screen.
The ‘Result’ key is used to call alignment results into the display.
ROTALIGN Ultra iS computer

ROTALIGN Ultra iS Shaft handbook
16
2.2.2 Computer LEDs
The battery status LED blinks green during the battery recharging process,
staying steady green when battery is fully charged.
The Bluetooth communication LED blinks blue while searching the neighbour-
hood for Bluetooth devices, staying steady blue when connected to the
sensALIGN sensor.
The four alignment condition LEDs are used to indicate the position of the laser
beam on the detector during beam adjustment, and the actual alignment status
after measurement.
LED Laser beam adjustment Alignment status
Blue Laser beam centred Excellent
Green Laser beam OK Acceptable
Amber Laser beam out of recommended
measurement part of detector
Bad
Red Laser beam off Grossly misaligned
2.2.3 Power supply
ROTALIGN Ultra iS is powered using a 7.2 V 6.0 Ah Lithium-ion rechargeable battery
ALI 4.603, which is to be charged only using the battery charger ALI 12.651-I. This
can be done with the battery inside the computer. The computer may continue to be
used if the battery is charged inside it.
Alternatively, use 6 standard ‘C’ size [IEC LR 14] batteries contained in the optional
battery compartment ALI 4.605.
If the ROTALIGN Ultra iS computer is not in use for extended periods of time,
a month or more, the rechargeable battery or the standard batteries should be
removed from the unit.

CAUTION
I
f
the ROTALIGN Ultra iS computer is not in use
f
or extended periods o
f
time,
a
month or more, the rechar
g
eable batter
y
or the standard batteries should be
r
e
m
o
v
ed
fr
o
m
t
h
e
u
ni
t
.

17
ROTALIGN Ultra iS computer
2.2.4 Replacing batteries
The rechargeable battery ALI 4.603 and the battery housing ALI 4.605 have identical
shapes and are therefore replaceable. If batteries require removal, turn over the
computer taking care not to damage the display and the hard keys. Undo the two
screws by turning them counterclockwise a quarter of a turn. With the screws
loosened, lift and pull the rechargeable battery or the battery housing (depending on
power supply source) out. The reverse procedure is used to mount back the recharge-
able battery or the battery housing back into the computer.
Lift battery housing or
rechargeable battery after
undoing the screws
Replace battery housing
or rechargeable battery by
sliding it into the groove
appropriately
Battery housing
ALI 4.605
If you are using the
standard ‘C’ size batteries,
it is recommended to
replace all of them at once.
Note the battery polarity
when inserting them in the
battery housing ALI 4.605.
The housing is removed
and replaced in the same
manner as the rechargeable
battery ALI 4.603
6 ‘C’ size [IEC LR 14]
batteries

ROTALIGN Ultra iS Shaft handbook
18
2.2.5 Mounting and dismounting the AC power supply/charger plug
The AC power supply/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.
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.
2
1
The direction arrow on the
plug has the inscription
‘OPEN’ marked above it.
Latching nipple

19
ROTALIGN Ultra iS computer
ROTALIGN Ultra iS top panel connectors
Sensor socket
Ensure correct sensALIGN
sensor cable (ALI 4.921-2)
plug orientation to avoid
damaging pins
USB host/slave port/
charger socket
The red dot on the USB
cable plug must match the
red dot on the USB port
USB host/charger socket
The red dot on the charger
plug must match the red
dot on the battery socket
1 32
1
2
3
Note that available cables
may be connected to the
corresponding numbered
sockets as follows:
ALI 4.921-2
(sensALIGN sensor and
laser cable)
ALI 12.503 (short
USB cable), ALI 12.651-I
(charger)
ALI 12.502 (long USB
cable), ALI 12.503( short
USB cable), ALI 12.651-I
(charger)
Connecting the battery
charger to ROTALIGN Ultra
iS computer – The LED next
to the battery symbol on
the keypad blinks while
charging takes place.