7705 Manual

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 info@pruftechnik.com
www.pruftechnik.com
1
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
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.
2
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
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 3
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
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
4
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
 Note
‘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
2
0001 12.601
ALI
ALI 12.201 Computer stand

1.00
ALI 12.601
OPTALIGN® smart RS
ALI 12.805 ALI 12.200 ALI 12.201

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 3.910 ALI 3.953
ALI 3.952 ALI 12.651-I

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
7
ALI 12.502-2
ALI 12.503 ALI 17.451
ALI 2.911 ALI 2.118 ALI 3.589

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 12.905.en DOC 12.106.en
DOC 12.601
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
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Nicht ins
May wiedera Feuer
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non recharg
recharg eable.
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4014 C AM2
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recharg eable.
eable.
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Bab
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V
eable.
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ALI 12.600

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 Note
Bluetooth may arrive at destination with discharged batteries. Charge the com-
ponents with the respective AC power supply/charger. 9
Page intentionally left blank
10
Safety notes
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. HNote
This symbol denotes information which must be followed in order to avoid

damage to equipment.
a
s
CAUTION
This symbol denotes information which must be followed in order to avoid

personal injury.
WARNING
11
This laser safety warning symbol denotes laser radiation.
Numbers in red circles indicate the corresponding operating step described in

1
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.
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
s
WARNING
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.
12
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.
H Note
Operating considerations
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
H
circumstances. PRÜFTECHNIK strongly recommends that you keep a backup or
printed records of all important data.
Note
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. 13
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.
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.
The laser beam hazard

symbol label is affixed at
the front of the RS5 laser
head.
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
The laser safety warning
LASER RADIATION to Laser Notice No. 50, dated June 24, 2007
label, the laser identi-
DO NOT STARE INTO BEAM
AVOID EXPOSURE fication label and the
LASER LIGHT IS EMITTED FROM THIS APERTURE
laser inspection label are
affixed to the back of the
Type ALI 3.910 17 RS5 laser ALI 3.910.
S.No. 3910 0108
HWS 1.00
Date März 2016
of manufacture Check calibration
PRÜFTECHNIK AG
85737 Ismaning
www.pruftechnik.com
Made in Germany
Located at the back of both The RS5 BT sensor iden-

14 Type ALI 3.901 17
the RS5 BT sensor ALI 3.901 tification label and the
S.No. 3910 0108
and the RS5 laser ALI 3.910 HWS 0.80 sensor inspection label are
is the respective inspection Date März 2016 affixed to the back of the
of manufacture Check calibration
label (shown opposite in red PRÜFTECHNIK AG sensor ALI 3.901.

85737 Ismaning
– note that the white arrow www.pruftechnik.com
Made in Germany
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.
Component labelling
This label is located at the

back of the OPTALIGN
smart computer battery
housing.
The OPTALIGN smart

Type S.No.
computer identification
label is located at the
bottom of the computer.
15
This page intentionally left blank
16
Introducing OPTALIGN smart RS5 BT
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.
h i f g — 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.
17

1. Alignment condition LEDs

1 2 3 4 5
2. USB port / Sensor socket /
Charger socket
3. Function keys [d, m, k]
4. Up / Clear / Menu keys
6
5. Navigation keys
6. On/Off/Enter key
7 7. Data entry keys
8. Wireless communication
indicator LED
OPTALIGN® smart RS
9. Battery status LED
9 8
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.
Lift housing or rechargea-

18 ble battery after undoing
the screws
Replace compartment or
rechargeable battery by
sliding it into the groove
appropriately 6 ‘AA‘ size batteries
2
Battery housing
0001 12.601
ALI
1.00
ALI 12.600
Nicht
Nicht ins
May wiederFeuer
Ne explod werfen
pas aufladb
jeter e in !
au fire! Notar.
feu!
non recharg
recharg
eable.
eable.
Bab
y LR
No14
4014 C AM2
1,5
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Rechargeable battery
Bab
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Nicht ins
May wiederFeuer
No 14
Ne explod
pas
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aufladb
!
4014 C AM2
au fire! Notar. 1,5
feu!
non recharg V
recharg
eable.
eable.
Bab
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No 14
4014 C AM2
1,5
V
ALI 12.601 pas

Nicht
Nicht ins
May wiederFeuer
Ne explod
jeter e in
werfen
aufladb
au fire! Notar.
feu!
!
non recharg
recharg
eable.
eable.
Bab
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No 14
4014 C AM2
1,5
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Bab
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No14
4014 C AM2
1,5
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Bab
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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!
m
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.
a
CAUTION
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.
H Note
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 19
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. Latching nipple
1
2
The direction arrow
on the plug has the
inscription ‘OPEN’ marked
above it.
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
s
WARNING
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.
a
CAUTION
3.3.2 Laser batteries

20 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.
a
CAUTION
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.
a m
Under no circumstances may the two smaller housing hex head screws be
removed, as that would void all warranty coverage.
Used batteries should be disposed of in an environmentally-sound manner!
CAUTION
RS5 laser ALI 3.910

“Beam active” indicator LED
Vertical beam position adjustment
thumbwheel
Rubber housing
Horizontal beam position

thumbwheel
RS5 laser dust cap in “open

position”
Laser emission
aperture
On/Off push button switch
Locking knob
Batteries are replaced 21

by undoing the 1/4 turn
screw and then opening
the battery compartment
cover. Pull the red battery
compartment strap to
remove the batteries.
1/4 turn screw
Battery compartment cover
1/4 turn screw Strap

3.3.3 RS5 BT sensor ALI 3.901

The sensor has an integrated Bluetooth, and contains two position detectors, which
measure the exact position of the laser beam as the shafts are rotated. The sensor also
contains an electronic inclinometer for shaft rotation measurements.
The sensor has two indicator LEDs on its front side. When facing the sensor, the left
LED shows both the laser beam adjustment and charging statuses. The LED lights
red, orange or green depending on current function. The LED on the right shows the
Bluetooth communication status and lights blue when scanning and when commu-
nication is established.
The sensor is powered using its internal 3.7 V 5 Wh Lithium-ion rechargeable battery.
Laser beam adjustment and

Distance marking
charging LED
Rubber housing
Bluetooth communication LED
Scratch-resistant lens
Micro USB port
Sensor dust cap in “open

position”
22
On/Off push button switch
Locking knob
3.3.4 Sensor LEDs
Activity Laser beam adjustment and charging LED Bluetooth communication LED
Switch on Lights up red for 1 second, then red or green Lights up blue for 1 second then turns off
(depending on the battery capacity) for
another second, then continues to blink red
Laser beam Blinks red when laser is OFF Blinks blue when scanning and when
adjustment Bluetooth communication is established
Blinks orange when laser is in END position
Blinks green when laser centered or in ‘laser
OK’ position
Charging Blinks fast green during fast charge (0% -

90%)
Blinks slowly green when charge is > 90%
Lights steady green when charge is 100%
3.3.5 Charging the sensor

The sensor may be charged using mains supply or a PC.
Charging the sensor using mains supply is faster than when charging through
a PC.
H Note
Connect the micro USB cable ALI 3.952 to the sensor then plug the other end of
the micro USB cable to the RS5 BT sensor charger ALI 3.953. Plug the adapter to the
mains. Alternatively, plug the micro USB cable into a USB port on a running computer.
During charging the battery status LED blinks green fast. When the battery capacity
reaches 90% the LED blinks green slowly and lights steady green when fully charged.
23
Charging sensor using Charging sensor through

mains supply and charger a PC
ALI 3.952 ALI 3.952
ALI 3.953
3.3.6 Powering the sensor using OPTALIGN smart computer

If required, the sensor may be powered via OPTALIGN smart computer. If the sensor
capacity is not sufficient to complete a measurement power the sensor as follows:
1. Connect the micro USB cable ALI 3.952 to the sensor.
2. Connect the ‘short’ USB cable ALI 12.503 to OPTALIGN smart computer, then
connect both USB cables (ALI 12.503 and ALI 3.952) together.
3. Press the sensor on/off push button. The left LED (charging status) blinks red
and communication is re-established between the sensor and OPTALIGN smart
computer.
RS5 BT sensor
ALI 3.952
OPTALIGN smart
computer
ALI 12.503
24
3.3.7 Opening the RS5 BT sensor/RS5 laser aperture

Opening the RS5 BT sensor or the RS5 laser aperture functions in a similar manner. In
the following example, images of the RS5 BT sensor are used.
Step 3: Lock the dust cap

in its “open position”
highlighted in red below.
Step 1: Lift the dust cap

slightly in the direction
shown by the bold red Step 2: Rotate the dust cap
arrow. in either direction as shown
by the bold red arrow.
25
3.3.8 Mounting and dismounting the universal charger ALI 3.953

The universal charger ALI 3.953 is used to charge or power RS5 BT sensor. The charger
comes with four different regional plugs. The available plugs are for the Euro zone,
the US, Australia and the UK.
Push the latch release downward and hold [ 1 ]. Insert the plug into the housing with
the lip on the leading edge [ 2 ]. The arrow inside the charger housing shows the
direction in which the plug is to be inserted with the latch release pushed downward.
The plug is locked into position when the latch release springs back into position.
To dismount a plug, push the latch release downwards [ 1 ]. The plug pops out.
1
2 The standard USB plug end
is connected to the charger
and the micro USB plug end
is connected to the RS5 BT
sensor.
3.3.9 Service and care
26
The accuracy of the system components should be checked every two years as
indicated by the date wheel label (shown at right) located on the back of the
housing.
H
Note
Month
Please return the system to your authorized PRÜFTECHNIK service center for in- 17 Year
spection by the date indicated.
3.4 Mini compact chain-type bracket ALI 2.118
Compact and lightweight, this bracket is designed to provide extremely rigid support
for the measurement components with a minimum of mounting time and effort.
The chain-type bracket fits onto shafts and couplings ranging from 15 to 200 mm (
19/32” to 7 7/8”) in diameter. Chains of varying lengths are also available. Mounting
instructions are given in ‘Horizontal machine alignment’. Other bracket types are also
available. Contact PRÜFTECHNIK Condition Monitoring or your local representative
for details on additional accessories.
OPTALIGN smart RS5 BT package with rechargeable battery computer ALI 12.015-
RS5R items are shown in section 1.1.
H Note
H
When transporting any magnetic brackets and components from PRÜFTECHNIK
Condition Monitoring, especially by air transport, please ensure that the magnet-
ic field strength of such brackets and components are kept well below the stipu- Note
lated limits by using the provided cover plate. The relevant safety data sheets
for different PRUFTECHNIK Condition Monitoring magnetic brackets and other
magnetic components may be downloaded from the PRÜFTECHNIK website at
www.pruftechnik.com.
Optional magnetic sliding
bracket ALI 2.230
Optional magnetic bracket
Compact chain-type
set ALI 2.761 SETIS
bracket ALI 2.118
comprises 2 no. ALI 2.761
27
Optional extra-thin bracket

ALI 2.109 SET
Optional compact magnetic

bracket ALI 2.112
Page intentionally left blank
28
Getting started
Chapter 4: Getting started
4.1 Set-up
1. Prepare the machines by making certain that they are locked out, tagged out
and all necessary safety precautions have been taken.
Refer to section 5.4 for
2. Mount brackets, sensor, and laser. The RS5 BT sensor should be mounted on
details on mounting
the right machine (usually movable). The laser is mounted on the left machine
components.
(usually stationary).
3. Switch OPTALIGN smart computer on by pressing e. The system beeps
followed by the flashing of an alignment condition LED. Shortly afterwards, the
machine dimensions screen appears.
RS5 laser mounted on RS5 BT sensor mounted

left machine (usually on right machine (usually
stationary movable)
29
OPTALIGN® smart RS5

4.2 Set RS5 BT sensor as default
1. Press q twice to show the expanded menu, then use the f/g and
highlight ‘Configuration’.
2. Confirm selection by pressing e, and then use the navigation keys and
highlight the ‘Default settings’ icon.
30
3. Confirm selection by pressing e. The “Default settings” screen opens. Use

f/g and highlight the item ‘Default sensor’, and then press e to
confirm selection. A selection box with three different sensor options appears.
Getting started
The type of sensor used

may also be set via the
“Dimensions” screen
context menu item ‘Change
sensor type’.
4. Use f/g and highlight the option RS5 BT. Confirm selection by pressing
e.
4.3 Enter dimensions
Press d to access the machine dimensions screen.

Use the data entry keys to directly enter all required dimensions.
31
The editing box appears as soon as a data entry key is pressed. Confirm entry by
pressing e. The rectangular highlight box moves to the next dimension. The
navigation keys can also be used to cycle through all dimensions.
Dimensions to be entered include:
1. Sensor-to-coupling center
2. Coupling diameter (default is 100 mm / 10” {for US units})
3. RPM (default is 1500 / 1800 {for US units})
4. Coupling center-to-front foot (machine designated movable)
5. Front foot-to-back foot (machine designated movable)
4.4 Wireless measurement
Initially switch the laser on by pressing its On/Off push button switch. Open the laser Refer to section 5.9. for
aperture and then adjust the laser beam onto the sensor dust cap center by repo- details on laser beam
sitioning the components vertically by moving them along the support posts, and adjustment.
horizontally by loosening the compact chain-type bracket.
Laser
Avoid looking directly at the laser beam.
When the laser beam is centered on the sensor dust cap, tighten brackets and
s
WARNING
components.
Now press m to access the “Measurement screen”. When in “Measurement”
screen, press q then use f/g to highlight the context menu item ‘Sensor
selection’.
32
Getting started
Confirm selection by pressing e. The selection window below appears.
With the item ‘Press Enter to scan for sensors’ highlighted, press e to scan for
sensors within the neighbourhood.
Make sure the sensor is switched on.
Once detected, the sensor is selected automatically.

H
Note
33
Laser
Open the sensor aperture then center the laser dot on target using the two yellow
fine adjustment thumbwheels. Position the laser dot at the center of the target
square or as near the center as possible. The blue OPTALIGN smart computer
alignment condition LED lights up and the green LED on the sensor blinks slowly.
34
If using Continuous Sweep mode and Auto Sweep is on [set under the “Configura-
tion” screen item ‘Shaft settings’], measurement is automatically initiated when the
shafts are rotated. If Auto Sweep is set off, press e to initiate Continuous Sweep
mode.
Rotate the shafts through a complete turn or as far as possible. A minimum rotation
of at least 70° is required.
Getting started
Press e to finish measurement.
4.5 Results
Press k to view alignment results.
The ‘all-in-one’ results

screen activated under
‘Shaft settings’ shows both
vertical and horizontal
coupling and foot results.
35
Coupling results are given in the form of gap and offset. Gap is positive when open
at the top or side away from viewer. Offset is positive when at the coupling point, the
shaft of the right machine is higher or further away from viewer.
Individual vertical and horizontal foot and coupling results are accessed by pressing
either k or f or g.
Vertical position results

( the ‘OK’ smiley indicates
alignment within tolerance
but can be improved by
aligning the machine to
obtain a happy smiley )
Horizontal position results

( a sad “smiley” indicates
alignment out of tolerance)
Both vertical and horizontal results show the foot position relative to the centerline of
machine designated stationary.
36 Positive values indicate that feet of machine designated movable are upwards or
away from viewer. Negative values indicate that feet of machine designated movable
are downwards or towards the viewer. The alignment condition is indicated by the
tolerance symbol and the corresponding lit OPTALIGN smart computer alignment
condition LED.
A happy smiley (with blue LED lit): values within excellent

tolerances
An “OK” icon (with green LED lit): values in acceptable

tolerances
A sad smiley (with red LED lit): values out of tolerance

Getting started
4.6 Context menu items
A useful feature in OPTALIGN smart computer is the availability of display screen

related context menu items for each individual screen. Useful menu items that include
accessing the “Configuration” screen to configure the computer, as well as turning
the computer off, can be accessed via the context menu that appears when q is
pressed at any time.
The context menu items are accessed using the navigation keys. The navigation
direction is either upwards/downwards or sideways. Alternatively, use may be made
of the data entry keys which provide navigation shortcuts.
All context menu items are labelled with digits for quick access. The required
menu item is accessed directly by pressing the corresponding data entry key.
H Note
Context menu items are If using the shortcut keys

available for every screen. pressing 7 -> 2
In this example, the context prompts the ‘change train
menu items available from orientation’ hint.
the “Dimensions” screen
are displayed. To change
machine train orientation
from Horizontal to Vertical
highlight ‘Train orientation’
-> ‘Vertical train’.
37
Context menu items
available from the “Results”
screen
The item ‘Move’ is used to
prompt Live Move, which
may also be accessed
directly by pressing the
corresponding data entry
key 2.
38
Horizontal shaft alignment
Chapter 5: Horizontal machine alignment
5.1 Preparing for the alignment procedure
Before using the system, prepare the machine for alignment as described below.
Make sure machines are locked out and tagged out and cannot be started
accidentally or deliberately while you are working on them! s
WARNING
5.1.1 Solid, flat foundation

A solid, rigid foundation is required to obtain correct, lasting shaft alignment that
allows long-term uninterrupted machine service.
5.1.2 Machine mobility

If the machine to be moved stands directly on the foundations, it cannot be lowered
for alignment correction. It is therefore advisable to start with about 2 mm (50 mils)
of shims beneath the feet of both machines. Hydraulic or screw-type positioning aids
are recommended for horizontal movement.
5.1.3 Rigid couplings

Rigid couplings must be loosened before measurement so that they do not distort the
alignment condition.
5.1.4 Shaft play and coupling backlash

Axial shaft play of up to 3 mm (1/8”) has no adverse effect on alignment results (but
not necessarily for machine operation!). 39
Because of the measuring principle, the system can distinguish between coupling
backlash and misalignment. During shaft rotation, the laser beam must however,
strike the sensor detector during some portion of the rotation.
5.1.5 Soft foot

Soft foot causes the machine frame distortion every time the anchor bolts are
tightened, making proper alignment difficult or impossible. (Refer to sections 5.16
– 5.17 for details.)
5.1.6 Thermal growth, alignment targets, tolerances

These values can be obtained from the individual machine specifications, and then
entered into the program. (Refer to sections 5.7.2, 5.7.4 and 5.7.5 respectively for
details.)
5.1.7 Measurement separation

Since the system requires no mechanical connections (such as cantilevered dial Note: A maximum laser-
indicator brackets) to span over the coupling during measurement, alignment may sensor separation of 10 m
easily be performed over large laser–sensor separations. (33 feet) is recommended.
Note that over very large distances the shafts and coupling may sag, and the machines
may need to be deliberately misaligned to take this into account, if such sag does not
disappear when machines are put into operation. Refer to the machine manufac-
turer’s specifications.
5.2 Check for soft foot
Refer to sections 5.16 – 5.17 on soft foot.
5.3 Mount the brackets
H
OPTALIGN smart RS5 BT system is delivered with fully assembled brackets, and
with the RS5 laser, RS5 BT sensor already assembled. In this case, the bracket
holding the RS5 laser is mounted on the shaft on the left side of the couplings Note
or the solid coupling hub on the left side. The bracket assembly holding the RS5
BT sensor is mounted on the shaft on the right side of the couplings or the solid
coupling hub on the right side.
Mount the brackets on either side of the coupling on either the shafts or on the solid
coupling hubs, and both at the same rotational position.
40 Please note the following in order to obtain the highest possible measurement
accuracy and to avoid damage to equipment:
Ensure that the brackets fit solidly onto their mounting surfaces!
Do not use self-constructed mounting brackets, or modify the original
a
s
CAUTION
bracket configuration supplied by PRÜFTECHNIK (for example, do not use
support posts longer than those supplied with the bracket). Contact your
local PRÜFTECHNIK representative if longer support posts are required.
WARNING
After mounting the brackets with the components, proceed to section 5.5.
If however, the brackets have not been fully assembled, follow the mounting
procedure in sections 5.3.1 and 5.4.
H Note
5.3.1 Bracket mounting procedure

To fit the compact chain brackets, refer to the diagram shown below and follow the
instructions carefully.
1. Choose the shortest support posts which will still allow the laser beam to pass
over or through the coupling. Insert the support posts into the bracket.
2. Fasten them in place by tightening the hex screws on the sides of the bracket
frame.
3. Place the bracket on the shaft or coupling, wrap the chain around the shaft
and feed it through the other side of the bracket: if the shaft is smaller than the
width of the bracket frame, insert the chain from the inside of the bracket as
shown in the diagram; if the shaft is larger than the bracket width, insert the
chain into the frame from the outside.
4. Catch the chain loosely on the anchor peg.
5. Turn the bracket thumbscrew to tighten the assembly onto the shaft.
6. Clip the loose end of the chain back onto itself.
The bracket should now be tight upon the shaft. Do not push or pull on the bracket
to check, since this could loosen its mounting.
To remove the brackets, loosen the thumbscrew, then remove the chain from its
anchor peg.
H
The compact chain-type brackets cover most situations, but in cramped or
special cases, other types of brackets may be required. Ask your PRÜFTECHNIK
Note
representative for details.
41
Anchor peg
1
3 4
2
5.4 Mount laser and RS5 BT sensor
1. Mount the RS5 BT sensor on the support posts of the bracket fixed on the shaft
of the right machine (usually moveable machine). The yellow locking knobs
should be loose enough to allow the sensor slide onto the support posts.
2. Clamp the sensor onto the support posts by tightening the yellow knobs.
3. Mount the RS5 laser on the support posts of the bracket fixed on the shaft of
the left machine (usually reference machine) – as viewed from normal working
position. Ensure that the yellow locking knobs are loosened enough to let you
slide the housing onto the support posts. Ensure that the laser can pass over or
through the coupling and is not blocked.
1 2
42
Both the sensor and laser should be at the same height, as low as possible, yet high
enough for the beam to clear the coupling flange. They should also visually appear to
be rotationally aligned to each other.
Make the final adjustments, loosening the brackets slightly if necessary, then rotating
them, and retightening.
In some cases, if the

coupling is large enough,
a coupling bolt can be
removed and the laser
beam shot through the
bolt hole, in order to
avoid protruding radially
beyond the coupling‘s
outer diameter (O.D.).
43
5.5 Switch the computer on and start application
Switch on the computer by pressing e. The system beeps followed by the flashing
of the blue LED. Shortly afterwards, the shaft alignment machine dimensions screen
appears.
5.6 Enter machine dimensions
Machine information and dimensions are entered using the grey data entry keys.
The required dimensions are entered directly using the data entry keys. With the
required dimension highlighted, enter dimension by pressing the appropriate data
entry keys. The editing box appears as soon as the first key is pressed.
44
Confirm the entered value by pressing e. The highlight advances automatically to

the next required dimension. Alternatively, any dimension can be accessed by using
the navigation keys.
The dimensions to be entered vary according to machine and type of coupling. In a

standard horizontal alignment application enter dimensions as follows:
5.6.1 Coupling center to sensor

Distance marking
This is the distance between the marking on top of the sensor and the coupling center.
Should there be need to edit the value, simply highlight it using the navigation keys,
then use the data entry keys to edit the value directly.
5.6.2 Coupling diameter

The coupling diameter can be obtained by measuring the circumference of the
coupling and dividing the value by 3.142 (p).
The default value is 100 mm (10” if set to US units). Should there be need to edit the
value, use the navigation keys to highlight the value, then use the data entry keys
to edit the value directly. Confirm the value by pressing e. The highlighting box
advances to the next required dimension automatically.
The default coupling diameter (also referred to as the reference diameter) may be set
under the “Default settings” screen.
5.6.3 RPM (revolutions per minute)

The default value is 1500 (1800 if set to US units). Should there be need to edit the
value, simply highlight it using the navigation keys, then use the data entry keys to
edit the value directly.
Default RPM may be set under the “Default settings” screen.
5.6.4 Coupling center to front foot, machine designated movable

This is the distance from the center of the coupling to the pair of machine feet nearest
to the coupling on the machine designated movable. 45
5.6.5 Front foot to back foot, machine designated movable

5.6.6 Entering negative dimensions

In certain circumstances or unusual machine configurations, negative dimensions may
also be entered where needed, such as coupling center-to-front foot (right machine)
when this foot is in front of the coupling center, or coupling center to sensor if the
sensor is mounted on the coupling such that the sensor distance marking is infront of
the coupling as shown in the diagrams 1a and 1b below.
5.6.7 Spacer shaft

If the spool piece of a spacer coupling is removed, and offset support posts used
to clear any radial obstructions, the situation illustrated in diagram 2 below could
occur.
1a
In the configuration shown,

the dimension coupling
center-to-sensor has a
negative value.
1b
46
2 B
In the case shown, B>A

A
and C>A. This spacer shaft
situation is effectively
handled by OPTALIGN smart
RS5.
Spacer removed
C
5.7 Machine set-up
All machine elements may be accessed within the dimensions screen using the
navigation keys.
Pressing q while in the dimensions screen reveals the menu items shown in the
next screen.
The expanded sub-menu

with the items ‘Flip
machines’, ‘Horizontal
train’ and ‘Vertical train’
appears when the menu
item ‘Train orientation’
is highlighted. The
47
sub-menu items are
accessed using h ->
g/f.
The menu items are accessed by highlighting the respective item using f or g
then pressing e to confirm selection. Alternatively, press the respective shortcut key.
‘Resume last file’ opens file last saved before system was switched off
‘New file’ used to create a new measurement file
‘Soft foot measurement’ prompts the measurement of soft foot
‘Pipe strain wizard’ opens the wizard
‘Add last machine’ is used to add a machine to the current train. (The added
element appears on the right side of the train. Note that if the machine train has
three machines, the context menu item ‘Delete machine will be included within
the listed menu items.)
‘Train orientation’ is used to flip machines (see ‘Flipping machines’ section 5.8)
or to select either a vertical or horizontal machine train orientation. For instance,
you may wish to select ‘Vertical train’ for vertical flange-mounted machines.
‘Change sensor type’ is used to allow measurement using RS5 sensor or
ROTALIGN sensor or OPTALIGN sensor.
5.7.1 Machine properties
The editing of specific machine parameters is possible only if the respec-

tive options have been purchased and licenced. Please consult your local
PRÜFTECHNIK representative for details.
H
Note
In this handbook the ‘optional’ icon is used to highlight features not available in
the standard version.
With the machine highlighted, pressing e reveals the machine parameters that can
be edited.
Parameters that can be

edited for stationary
machines include:
fixation
flange position
type of machine
machine name
48
5.7.1.1 Editing machine type

To choose type of machine to be displayed, use f/g highlight the context
menu item ‘Choose machine type’ then press e to confirm selection. The ‘Machine
selection’ pane opens.
Use f/g to scroll through the available machine type graphics. Following
machine graphics are available: pump, motor, gearbox and a generic standard
machine.
If you need to change the orientation of the machine graphic use i/h.
49
Parameters that can be

edited for moveable
machines include:
fixation
flange position
thermal growth values
type of machine
machine name
Soft foot measurement can

also be carried out from this
screen.
5.7.1.2 Editing machine name

To edit the machine name, use f/g to highlight the context menu item ‘Enter
name’. Confirm selection by pressing e. The editing box appears and the machine
name may be edited.
When entering names that

contain both upper and lower
case characters as well as
numerals, use o to cycle
through the three options.
Press and hold down o while
observing the status indicator at
the top left corner of the editing
box. This displays the type of
character to be entered.
Empty spaces are entered by
pressing 0.
Use the data entry keys to edit the machine name.
5.7.2 Thermal growth

Thermal growth values can be entered only when the machine is defined as moveable.
To enter thermal growth values, highlight the context menu item ‘Thermal Growth’
using either f or g.
Note: To be able to enter

50 thermal growth values,
coupling target values
and dial gauge values, an
optional firmware module
is necessary. Please order
part number ALI 12.713
[Targets, Thermal Growth
and Dial Gauge Target
Input] to activate the
features.
Press e. The “Thermal growth” screen appears.
Use the navigation keys to highlight the ‘feet pair’ where thermal growth is to be
entered. The editing box appears when any data entry key is pressed. Use the data
entry keys to enter the thermal growth value in the vertical orientation, cycling
through the feet pairs using the navigation keys.
51
To enter values in the horizontal orientation, press q while in the “Thermal growth”
screen. The context menu as shown below appears.
Use f/g to highlight the context menu item ‘Horizontal thermal growth’
then press e to confirm selection. The horizontal thermal growth view opens. Now
proceed to enter values as described for vertical orientation previously.
The editing box may also Carefully observe sign

be opened by highlight- convention (+ and -) when
ing a foot value using entering thermal growth
the navigation keys then values. Thermal growth
pressing e. values are NOT a target;
instead they represent the
amount and direction of
the anticipated movement
that the machine will
undergo when put in
operation.
Press ß after entering all values.
Thermal growth values may be disenabled from the “Thermal growth” screen by
highlighting the tick [ ] then confirming selection by pressing e.
52
Alternatively, press q while in the “Thermal growth” screen. The context menu
appears.
Alternatively, with the

context menu open, press
1 followed by 2 to
disenable thermal growth
values.
Use f/g to highlight the context menu item ‘Thermal growth’ then use h to
switch to the submenu pane. Highlight the submenu item ‘Disable’ using f/g
then confirm disenabling values by pressing e.
Thermal growth values may

be enabled from this screen
once again by pressing e.
53
5.7.3 Thermal growth calculator

Machine conditions change from the time the machine is off line to when it is running
under normal operating conditions. Some of these changes are due to process forces
(e.g. fluid pressures, airflow). The most notable of these changes is the change in
the temperature of the machine bearings and supports. This is called the machine’s
thermal growth.
The system is used to calculate thermal growth compensation if no other values are
available. Thermal growth is calculated from the following factors: material charac-
teristics, expected temperature difference, and height of the shaft centerline above
the shim plane.
Thermal growth is calculated as follows:

1. Access the “Thermal growth” screen for the machine whose thermal growth
requires calculating as described previously.
2. Press q while on the screen. The context menu appears. Use f/g to
highlight the context menu item ‘Thermal growth calculator’.
3. Confirm selection by pressing e. The thermal growth calculator pane appears.
54
4. Use the navigation keys to highlight the ‘Material’ information box then press
e. A drop down menu appears.
5. Use f/g to highlight required type of material.
6. Confirm selection by pressing e.

Use the navigation keys to highlight the respective value boxes and enter directly,
the ambient temperature, the machine running temperature and the distance
from machine base to the shaft centerline using the data entry keys.
In the example opposite, the

motor material is cast iron,
the ambient temperature is
25°C, the machine running
temperature is 120° C
and the distance from the
bottom of the machine feet
to the shaft centerline is 70
cm. This gives a growth of
0.71 mm. 55
Pressing q with the thermal growth calculator pane open reveals the available
context menu items.
The thermal growth pane

context menu items may be
used as desired.
5.7.4 Coupling properties

Coupling properties are entered and edited in the same manner as machine properties.
Use the navigation keys to highlight the coupling.
With the coupling highlighted, pressing e reveals the coupling parameters that can
be edited.
Coupling parameters that

can be edited include:
coupling targets
user defined tolerance
values
type of coupling [types
available are short flex,
56
cardan and spacer
shaft]
sensor type option
The menu may also be

used to reset the coupling
settings to default, i.e rpm is
1500, coupling diameter is
100 mm and the tolerance
table is based on 50 Hz.
5.7.4.1 Editing coupling targets

To enter coupling target values, use f/g to highlight the context menu item
‘Targets’ then press e. The “Coupling targets” screen appears.
The editing box may also Carefully observe sign

be opened by highlight- convention (+ and -)
ing a value position using when entering target
the navigation keys then values. Target values
pressing e. are NOT the anticipated
thermal growth values;
instead they represent the
amount and direction of
the desired misalignment
to be set at the coupling
to compensate for the
anticipated movement
Use the navigation keys to highlight respective gap/offset to be entered. Enter the machine will undergo
coupling target value directly using the data entry keys. The editing box appears when when put in operation.
any data entry key is pressed. Confirm entered values by pressing e.
5.7.4.2 Selecting coupling type

To select type of coupling desired, use f/g to highlight type of coupling
required from the menu.
The option ‘Change to

short flex’ does not appear
under the menu items as it 57
is the current setting. If the
current setting was either
‘spacer’ or ‘cardan’, the
item ‘Change to short flex’
would appear in the menu.
Press e to confirm selection.

Type of coupling selected in

this example is cardan.
If the coupling type selected is spacer shaft or short flex, it is possible to set the
coupling results format directly from the machine dimensions screen.
With the coupling highlighted, press e to reveal coupling parameters that may be
edited.
In this example, the selected

coupling type is ‘Spacer
shaft’ and therefore the
availability of spacer shaft
formats that may be used to
display coupling results.
58
Use f/g and highlight the item ‘Spacer format’.
If the coupling type was ‘Short flex’, then the item ‘Short flex format’ would
appear in the list. H
Note
Press e to confirm selection. The available spacer shaft coupling results formats are
displayed.
Offset B / Offset A Gap B / Gap A
Total Gap / Offset at Total Gap / Offset at Alpha / Beta

Left Coupling Right Coupling
Total Angle / Offset at Total Angle / Offset at

Left Coupling Right Coupling
59
Coupling results formats for spacer shafts, short flex coupling and cardan shafts may
also be set under the configuration item ‘Shaft settings’.
5.7.5 User defined tolerances

It may be necessary to specify individual tolerances. These user defined tolerances
may either be “symmetrical” or “non-symmetrical”. In “symmetrical” tolerances, the
tolerance value for the horizontal and vertical planes are equal. In “non-symmetrical”
tolerance, the two planes have different tolerance values.
To set type of user defined tolerance to either “symmetrical” or “non-symmetrical”,
use the configuration item ‘Shaft settings’.
The “Shaft settings” screen

is accessed via the menu
item ‘Configuration’. To
set ‘Symmetrical’ or Non-
symmetrical’ user defined
tolerances, highlight the
item ‘User tolerance type’
e. Use
and then press
f/g to highlight
desired type and then
confirm selection by
pressing e.
With type of user defined tolerance selected, return to the “Dimensions” screen and
highlight the coupling and then press e. The coupling parameters are displayed.
The coupling parameters

context menu is displayed
60
by pressing e with the
coupling highlighted.
Note that the “User

defined tolerances /
Tolerance table “ screen
may also be accessed
Use either f or g to highlight the context menu item ‘Tolerances’ then press via the “Results” screen
e. The combined “User defined tolerances / Tolerance table” screen appears. context menu item
‘Tolerance table’.
In this example, the

active tolerances are
the “symmetrical” user
defined values which have
already been defined.
The ‘user’ button in the
lower frame is yellow. The
system tolerance table
is deactivated as can be
seen from the grayed
The ‘user’ button
out smileys in the upper
frame.
To edit the user defined tolerance values, use the navigation keys to highlight gap
or offset. Enter user defined tolerance value directly using the data entry keys. The
editing box appears when any data entry key is pressed.
61
Confirm entry by pressing e.

If the set user defined tolerance type was “symmetrical”, then values would be
displayed for both horizontal and vertical planes.

active tolerances are the
“non-symmetrical” user
defined values. Gap and
offset values are for both
horizontal and vertical
planes specified.
The entered user defined values (for both “symmetrical” and “non-symmetrical”
types) are independent of rpm. When these values are enabled, that is when the
‘user’ button in the bottom frame is yellow, they override the system tolerance table.
Alternatively, the user defined tolerances may be deactivated by exiting the user
defined tolerances frame. This automatically enables the system tolerance table and
the smileys in the upper frame revert to yellow.
Press ß to exit the combined “User defined tolerances / Tolerance table” screen.
Note that the screen header toggles between “Tolerance table” and “User
defined tolerances”.
H
Note
Pressing f/g
toggles the cursor between
the two frames – “Tolerance
table definition” and “User
defined tolerance values”.
The context menu item ‘Disable tolerances’ may be used to deactivate both system
and user defined tolerance values.
62
The context menu items

‘Enable tolerances’ and
‘Disable tolerances’ toggle
depending on current
tolerance status.
Tolerances may also be directly enabled and disenabled from the “Tolerance table” or
“User defined tolerances” screen.
If tolerances are already

disenabled, a “no” symbol
[ ] appears instead of
the tick [ ]. Tolerances
may be enabled directly by
highlighting and the
pressing e to confirm
selection.
To disenable tolerances directly, use the navigation keys and highlight the tick [ ]
and then confirm selection by pressing e.
5.7.6 Tolerance table

The “Tolerance table” screen may be used to display the suggested active
PRÜFTECHNIK Condition Monitoring tolerance table.
While in the “Tolerance

table” screen, the
navigation keys may be
used to toggle between the
system and user defined
tolerance values.
63
These suggested alignment tolerances are general values based upon experi-
ence and should not be exceeded. They are to be used only if existing in-house
standards or the manufacturer of the machine or coupling prescribe no other
a
CAUTION
(tighter) values.
The tolerance table values are rpm dependent. Changing the rpm results in the cor-
responding gap/offset tolerance values. Use the navigation key to highlight the rpm
box. With the box highlighted, use the data entry keys and enter the required rpm
then confirm entry pressing e.
The new rpm is now applied in the machine set-up.

Other menu items related to tolerances may be accessed via the context menu which
is opened by pressing q from the “Tolerance table” screen.
64
The context menu item ‘User tolerance’ is used to set user defined gap and
offset tolerance values. When these defined values are active, the system
tolerance table is disenabled. The menu item ‘Disable tolerance’/’Enable
tolerance’ is the used to enable and disenable both system and user defined
tolerances.
The tolerance table can be printed directly to the configured printer or saved to
a memory stick (aka jumpdrive) as a PDF if the printer configuration is set to PDF
file (refer to section 5.14.2 ‘Printing reports’).
5.7.7 Entering coupling target values as dial indicator readings

Coupling target values given in terms of dial indicator readings can be entered into
OPTALIGN smart computer for conversion to gap and offset. If the function coupling
targets is enabled, the converted values are automatically taken into account when
determining the alignment condition. To enter dial indicator measurements proceed
by pressing q while in the “Coupling targets” screen.
The “Coupling targets”

screen is accessed as
described in section 5.7.4.
When the context menu appears, use f/g and highlight ‘Targets as dial
gauge’ and the press e to confirm selection. This prompts the “Dial gauge set-
up”screen.
Note that a hint to set up the dial gauge configuration will appear followed by
the “Dial gauge set-up” screen.
H Note
65
The dial gauge configura-
tion is set at the header.
Use the navigation keys
to highlight the header
then cycle through the
various configurations by
pressing e with header
highlighted. Alternatively,
use the “Dial gauge set-up”
screen context menu to
select desired dial gauge
configuration.
Use the navigation keys to exit the header and cycle
through the required dimensions. Enter the required
dimensions.
Press ß to access the “Targets as dial gauge values” display then enter the dial
indicator values in the respective value boxes using the data entry keys and confirming
each entry by pressing e.
66
Press ß to display the target values, including any bracket sag amounts entered in
terms of gap and offset.
The “Coupling targets” screen context menu may be used to disenable coupling
targets if desired.
The screen context menu is Targets may also be

accessed by pressing q. disenabled directly from
The context menu and the screen by highlight-
submenu items available ing the tick [ ] and
include: then confirm selection by
Enabling and disenabling pressing e.
coupling targets, and
entering coupling target
values as dial indicator
readings.
5.8 Flipping machines
If machines are installed such that access to the opposite side of the machines is
restricted, and there is need to designate the right machine as stationary, then the
flip function is used.

machine set has been
mounted next to a wall, and
the machine on the right is
stationary.
67
As the opening template in

the application dimensions
screen shows the stationary
machine on the left, the
flip function is used to
designate the machine on
the right as stationary.
Situations where the machine positions on screen require rearranging often occur
when using predefined machine templates or during set-up (as can be seen in the
previous illustration).
1. Press q while in the “Dimensions” screen, then use the navigation keys and
highlight ‘Train orientation’ -> ‘Flip machines’.
Note that once a

measurement has been
taken, the “Dimensions”
screen context menu item
‘Flip machines’ disappears
and the machine positions
cannot be switched around
again.
2. Press e to confirm selection. A “Flip machines” hint screen appears.
68
The hint reminds the user that the laser must always be mounted on the left
machine as viewed by the user, and sensor to coupling center distance must be
checked again.
H
Note
3. Press e or ß to confirm flipping machines.

The pump which is the

stationary machine has now
been flipped to the right
hand side but still remains
the stationary machine.
4. Ensure the laser is mounted on the machine on the left, then check the distance
between the sensor to coupling center.
5.9 Laser beam adjustment Note: Refer to the illustra-

tions on the next page.
1. Open the RS5 laser aperture by lifting and the rotating the dust cap until it
rests in its “open” position. Switch the RS5 laser on by pressing its On/Off push
button switch. Leave the sensor dust cap on its “close” position.
Do not stare into the laser beam!
2. If the RS5 laser and sensor have been roughly positioned to each other during
s
WARNING
mounting (see section 5.4 – ‘Mount RS5 BT sensor and laser ’), the laser beam
should strike the sensor dust cap. If the beam be so far off target that it misses
the sensor completely, hold a sheet of paper in front of the sensor to locate the 69
beam and readjust it onto the sensor as follows:

3. Reposition the components until the laser beam strikes the sensor cap:
›› vertically: loosen the locking knobs and adjust the height.
›› horizontally: loosen the bracket and turn the laser and/or sensor brackets into
line with one another.
4. Use the adjustment wheels on the RS5 laser to center the laser beam on the
sensor dust cap, and then open the sensor aperture by lifting and rotating its
dust until it rests on its “open” position.
Laser beam adjustment It is highly recommended

that before mounting
RS5 laser
the laser on its bracket,
1
both yellow adjustment
thumbwheels be brought
to the approximate center
of their travel range. This
will ensure that the beam
is emitted from the laser
as straight as possible
and not at an angle.
Also make sure both
2 3 brackets are rotationally
aligned to each other.
These precautions will
greatly facilitate the beam
adjustment process.
ON/OFF push
button switch
vertical
4
70 RS5 BT sensor
horizontal
5.9.1 Establishing wireless communication

1. Switch the RS5 BT sensor on by pressing its On/Off push button switch.
2. Press m to access the OPTALIGN smart computer measurement screen.
3. While in the “Measurement” screen, press q then use f/g to

highlight the context menu item ‘Sensor selection’.
71
4. Press e to confirm selection. The selection window appears.

5. With the item ‘Press Enter to scan for sensors highlighted, press e to scan for
sensors within the neighbourhood.
Make sure the sensor is switched on.
Once detected, the sensor is selected automatically.
72
6. If the laser beam has been correctly adjusted [as shown above right], you may
proceed with measurement as described in section 5.10.
5.9.2 Centring the laser beam dot

If the laser beam is not centered, use the screen hints to center the laser beam on the
position detector.
‘Laser off’ displayed when Blue

Green/Orange/Red
laser beam is out of range
– the beam adjustment LED
blinks red
‘Laser end’ displayed when
laser beam is at the edge of
range – the beam adjust-
ment LED blinks orange
Laser OK / centered when
beam is centered – the
beam adjustment LED blinks
green
The Bluetooth status
To ensure that the laser beam is not only centered but also reasonably perpendicular,
LED blinks blue when in
the “Measurement” screen context menu item ‘XY view’ may be used to check the
operation.
location of the beam on both position detectors. Full description of the XY view is in
section 6.2.5.
The battery icon present on

the “Measurement” screen
shows the charge capacity
of the RS5 BT sensor.
73
The beam does not have to be exactly at the center of the crosshair, as this will
H
not affect measurement accuracy. However, maximum range for measurement is
available when the beam is well centered.
Note
Once centered, the sensor and laser must not be touched, as any movement
during measurement will be interpreted as misalignment. These components
may however be moved when extending the measurement range (see section
6.2.1 ‘Extending the measurement range’).
5.10 Take measurements

Once the beam is centered, such that the laser dot on the display screen is at the
center of the crosshair and the blue OPTALIGN smart computer LED is lit, measure-
ment may be started. The standard measurement mode is the Continuous Sweep
method. If using Continuous Sweep and the function Auto Sweep is set on [set
under the “Configuration” screen item ‘Shaft settings’] measurement is automatically
initiated when the shafts are rotated. If Auto Sweep is set off, press e to initiate
Continuous Sweep mode.
For details on shaft

settings please refer to
section 8.2.7.
Other measurement modes are

available. The table below gives a guide
as to which measurement mode is ideal for which measurement. In this section we
describe the Continuous Sweep mode. Details on the other modes can be found in
section 6.1 ‘Measurement modes’.
Measurement mode Application

74
Continuous Sweep Standard machines
Multipoint Uncoupled shafts, nonrotatable shafts, sleeve

measurement bearings, white metal bearings, journal (radial)
bearings, shafts that are hard to turn, shafts with
herky-jerky (uneven) rotation, situations with long
spans or severe misalignment that will readily
cause the beam to fall out of range
Static measurement Vertical machines (flange mounted or four feet)

Rotate the shafts a full turn or as far as possible. A minimum rotation of 70° is required.
Remember not to touch
mounted components!
It is advised to turn shafts
in the same direction as
the machine normally
rotates, in case the shafts
shift from their normal
seating in the bearings.
You may begin
measurement by turning
the shafts even if the
beam is not centered
exactly at the center of
the crosshair.
As the shaft is rotated, the covered arc changes colour from red to yellow and finally
to green. A red sector signifies that the covered angle is insufficient for accurate
results. Results can be obtained when the sector is yellow, but it is recommended
that the shafts be rotated until the arc is green. Whenever possible, shafts should be
rotated through as wide an angle as possible. If you press e to finish measurement
and collect data, a screen similar to the following appears.
The black lines in the

rotational arc indicate the
positions where readings
have been taken. In case
of vibration, switch to 75
Multipoint measure mode
(refer to section 6.1.1) and
a higher averaging (refer
to section 6.2.4).
Alternatively, view alignment results directly by pressing k once measurement is

completed.
5.11 Results
5.11.1 Coupling results and feet positions

The following display shows the measured alignment condition along with numerical
values for the coupling and actual machine feet positions.
This complete alignment

condition screen appears
only when the option
‘All-in-one results’ is
activated in the ‘Shaft
settings’ configuration
For details on shaft
menu. If not activated then
settings please refer to
the screen displays only
section 8.2.7.
coupling results. Foot results
may then be accessed by
pressing k/f/g.
Coupling results are given in the form of gap and offset values in both vertical and
horizontal directions. The true gap being the difference in gap between the coupling
faces top to bottom (vertical) or side to side (horizontal) at the diameter that was
entered. Offset is the distance between the two shaft centerlines at the transmission
plane of the coupling.
5.11.2 Sign convention

The following sign convention is used in the evaluation of alignment results, and
76 assumes that the viewer is standing in front of the machines as they appear on the
display.
Gap is positive when open at top or side away from viewer, and offset is positive
when at the coupling point, the shaft of the right machine is higher or further away
from viewer.
Both vertical and horizontal results show the foot position relative to the centerline
of machine designated stationary. Positive values indicate that feet of machine desig-
nated movable are upwards or away from viewer. Negative values indicate that feet of
machine designated movable are downwards or towards the viewer.
If all four coupling values are within tolerance [indicated by the smiley icon and
the green or the blue LED], you do not need to align the machines.
H Note
If no in-house standards or specifications from the coupling or machine manufacturer

are available, the computer alignment condition LEDs and the smiley provides a
tolerance check based on standard industry norms. If the measured alignment falls
within acceptable tolerance, the green LED lights up. The blue LED lights up when
the measured alignment falls within excellent tolerance. The red or yellow LED lights
up when alignment is out of tolerance. In this case, the machines must be aligned.
If the coupling results show that misalignment exceeds the tolerance, then the
machine must be realigned by shimming vertically and repositioning the machine
horizontally. The different views may be accessed by pressing k/f/g.
In this example, the left

machine has no fixation
therefore its foot values are
not displayed.
In this example, the left

machine is stationary but
has two feet fixation. The
highlight is at both front 77
feet. The corresponding
foot value in this case is
0.00 mm.
5.11.3 Multiple feet results

If measuring a six-foot machine, it is possible to determine the correction value of the
middle pair of feet. Press q when in feet results.
Use f/g to highlight the context menu item ‘Multiple feet calculator’.
Confirm selection by pressing e. The multiple feet calculator pane opens.
With the multiple feet

calculator pane open, enter
the dimension between the
first and middle pair of feet.
The foot correction value
at the middle feet appears
in the box just below the
78
entered dimension.
5.11.4 Results table

The results table lists a maximum of three coupling result entries for currently selected
set of machines. These three entries may include the current coupling results and the
two most recent coupling results. The entries are in chronological order with the most
recent result appearing at the bottom of the list numbered as current ( ‘Cur.’). The
oldest result appears at the top of the list numbered 1st.
The results table is accessed through the “Results” screen. Press q while in results.
Use f/g to highlight ‘Results table’ from the context menu that appears.
Alternatively, the results

table can be accessed
directly by pressing 5
while the context menu is
displayed.
Press e to confirm selection. The results table is displayed.
You may use f/g

to highlight any one of the
listed coupling results. With
79
the results set highlighted,
pressing e displays the
measurement details. The
highlighted results set may
be deleted by pressing c.
Use f/g to scroll though the coupling results entries.
H
The individual results can not be averaged. Only the result listed as current [Cur.]
can be displayed on the “Results screen”. Should a measurement result listed
Note
as current [Cur.] be deleted, then the next recent measurement will be listed as
current and these results will be displayed in the “Results” screen.
The measurement details for each single results set may be displayed by highlighting
the results set using f/g then pressing e.
Alternatively, use the context menu item ‘Measurement details’. With the desired
results set highlighted, press q then use f/g to highlight the context menu
item ‘Measurement details’.
With ‘Measurement details’ highlighted, press e to confirm selection.
The measurement details

shown here have ensued
from a Continuous Sweep
results set. Note that the
standard deviation is also
displayed.
80
5.11.5 Alignment condition

The ‘smiley’ symbol on the coupling results screen indicates the degree to which
the measured alignment condition meets tolerances. The smiley face depicts either
alignment within tolerance or out of tolerance and appears only when tolerances
have been enabled (see section 5.7.4 ‘Coupling properties’).
Within excellent tolerance
Within acceptable tolerance
Out of tolerance
The computer LED system provides additional information on the tolerance status.
Tolerance
Within tolerance
Smiley
Happy face
Lit LED
Blue H Note
Within tolerance OK Green
Out of tolerance Sad face Amber
Worse tolerance Sad face Red
The ‘smiley’ TAKES INTO ACCOUNT any targets and thermal growth values
which you may have entered – see page 50 to page 57.
H Note
81
The tolerance table is accessed from the “Results” screen. Press q to display the
context menu.
Use f/g to highlight the context menu item ‘Tolerance table’, then press e
to confirm selection. The “Tolerance table” screen appears.
82
If user defined tolerances are desired, use f/g to toggle between the recom- Usage of “Tolerance table/
mended tolerance table values and the user defined tolerance values. You may also User defined tolerance
use the “Tolerance screen” context menu item ‘User tolerance’ to switch to “User values” screen is explicitly
defined tolerance values” screen. described in sections 5.7.5
and 5.7.6
With user defined tolerances now activated, press k to view alignment results.
The human bust icon next

to the smiley indicates
that the tolerances being
currently applied are user
defined tolerances.
83
5.12 Rotating machine view
The “Results” screen context menu item ‘Rotate view’ allows the user to view the
machines, and subsequently perform Move corrections from either side without
having to change the orientation of the OPTALIGN smart RS5 BT components.
This function is particularly helpful when the machines can be accessed from both
sides.
‘Rotate view’ functionality is available within the “Results” and “Move” screens.
After obtaining measurement results, press q then use f/g and highlight
‘Rotate view’.
With ‘Rotate view’ highlighted, press e to confirm selection. After confirming

selection, a video hint runs on the display.
84
When the video run stops, the orientation on the display changes to match the
opposite position. Results will now be displayed as currently viewed by the user. This
is from the opposite side of the original position.
The screen on the left shows the initial orientation as viewed by the user, while the
screen on the right shows the orientation after the ‘Rotation view’ function has been
applied. In the screen on the right, the machine designated stationary is now on
the right hand side. Note that the vertical coupling gap values for both orientations
remains unaltered as are the horizontal coupling offset values. The applied sign con-
vention holds valid for both orientations.
H
Any applied ‘Rotation view’ functionality is temporary and is available only
in the “Results” and “Move” screens. As soon as one reverts to either the
Note
“Dimensions” or “Measurement” or “Soft foot” screens, the original machine
orientation is reassumed.
5.13 Align machine
H
Machines can be aligned using the given foot results by proceeding as described 85
below. Remember, if alignment is in tolerance (indicated by a happy smiley

Note
symbol and the blue or green system computer LED), there is NO need to align
the machines.
To align your machine you need to move it vertically by shimming the feet, and
horizontally by shifting it sideways. You could do these operations in either order or
simultaneously, but the recommended procedure is as follows:
5.13.1 Shim first
H
It is recommended to perform vertical corrections first, since the horizontal
condition is easily affected by the process of loosening anchor bolts and inserting/
Note
removing shims, whereas the vertical condition is less prone to being affected
when performing horizontal moves. You may need to recheck soft foot before
proceeding.
5.13.2 Preparation and shimming

1. Prepare the machines for shimming by ensuring the following:
The foot bolts are clean, intact and removable.
Soft foot has been eliminated (refer to section 5.17).
The feet have enough shims under them should lowering the machine be
necessary.
Good quality shims such as PERMABLOC, MYLAR or LAMIBLOC are available
from PRÜFTECHNIK Condition Monitoring. (Visit www.pruftechnik.com for
details.)
2. Loosen foot bolts while trying to avoid moving the machine horizontally. If any
foot comes off the ground when loosened, suspect soft foot.
3. Use the vertical foot position values to shim BOTH front and back feet pairs as
required. Positive feet values indicate that the feet are high and therefore shims
should be removed, while negative feet values indicate that the feet are low and
suggest addition of shim thickness.
86
4. Retighten and remeasure to verify vertical results and determine the exact
alignment condition.
Note that vertical shimming can also be carried out with the Live vertical Move.
H
Note
5.13.3 Horizontal and vertical Live Move
The RS5 BT sensor technology allows Live Move corrections in both horizontal
and vertical directions concurrently with the sensor at any angular position.
H Note
The alignment corrections involving shimming and the lateral positioning of the
machines can be followed in a real-time interactive display. From the results screen,
press q. The context menu appears.
Use f / g to highlight ‘Move’ then press e to confirm selection. If Live

Move is initiated from the “all-in-one” results screen or the horizontal results screen,
the prompted Move direction will be Horizontal. Vertical Move direction may be
prompted by initiating Live Move in the vertical results screen.
If the laser beam is centered Live Move starts automatically. Proceed to carry out Live
Move in one direction (say Vertical shimming first) then in the other direction (say 87
Horizontal Move).
If however the laser beam is not centered, use the available on-screen hints to
center the laser beam. You could also use the ‘Move’ screen context menu item
‘XY view’ for this adjustment. Live Move resumes automatically once the laser
H
Note
beam has been centered.
5.13.4 Shimming using vertical Live Move

1. Having initialized Live Move from the vertical results screen, and the with foot
bolts of the ‘machine to be moved’ loosened, proceed to make the necessary
shimming corrections. Keep an eye on the smiley on the screen and the
computer alignment condition LEDs.
2. Use the vertical foot correction values to shim BOTH front and back feet pairs as
required. Positive feet values indicate that the feet are high and therefore shims
should be removed, while negative feet values indicate that the feet are low and
88 suggest addition of shim thickness.
3. If the smiley returns a happy face or an OK symbol, the current vertical

alignment condition is within tolerance.
5.13.5 Lateral positioning using horizontal Live Move

After making the vertical corrections, you may want to use the Live Move function to
carry out horizontal corrections.
1. Press q then use f/g to select ‘Change view’ followed by ‘Horizontal’.
2. Confirm selection by pressing e and proceed to carry out Live Move in the
horizontal direction.
89
3. Note the following sign convention – Positive feet values indicate that the
machine feet should be moved towards viewer, while negative feet values
suggest the moving the machine feet away from viewer.
4. Move the machine feet in the direction of the yellow arrows, keeping an eye on
the smiley on the screen. The arrows change with the movements automatically.
Watch the screen carefully to ensure that machine end and direction moved are
correct. The smiley on the display screen and the computer LEDs also give an
indication of the alignment condition as the machine is moved.
If desired you may toggle

between the Horizontal and
Vertical Live Move directions
using f/g.
Do NOT attempt to move the machine using heavy sledgehammer blows. This
can cause bearing damage, and also produce inaccurate Move results. Jack
bolts on the feet or other mechanical or hydraulic devices are recommended for
a
CAUTION
moving machines.
5. If the smiley returns a happy face or an OK symbol, the current horizontal

alignment condition is within tolerance
6. Tighten anchor bolts and to proceed to verify alignment condition after Move.
7. Press q then use f/g to highlight ‘Stop’.
90

9. With the option to re-measure highlighted, press e to confirm selection. The

measurement mode is initialized. Recheck alignment by taking another set of
measurements and viewing results. If they are in tolerance, then the machines
are aligned.
5.13.6 Saving data and printing

(See section 5.14.)
5.13.7 Finish alignment

Switch off the computer, the sensor and the laser, then remove the components from
s
the shafts and store them in the case.
Replace guards before you switch the machine back on.

WARNING
91
5.13.8 Points to observe during Live Move

1. Have shafts accidentally moved (rotated)?
The shafts, sensor and laser MUST remain steady during the entire Live Move
procedure. Should the shaft move from the set position while in Live Move, the angle
adjustment window comes up indicating the angle to which the shaft has rotated.
The shafts must be rotated back into the narrow green sector.
Live Move resumes automatically when the shafts are rotated back into this
sector.
H
Note
2. Extending measurement range

If the hint on the screen below appears during Live Move, then the laser beam has
drifted out of detection range due to great misalignment or long beam travel.
92
In this case, the measurement range can be extended as described in section 6.2.1.
3. Soft foot
If the machine suffers from excessive soft foot, the Live Move function may be
hampered by the fact that the machine changes position on its own every time the
bolts are loosened and tightened. Correct this before aligning. (See section 5.16 for
details.)
4. If poor repeatability is experienced

Possible causes include:
›› Incorrect or loose bracket mounting
H
›› Significant shaft play or coupling backlash
›› Soft foot can cause positioning errors that make repeat measurement
Note
necessary
›› Loose anchor bolts
›› Yellow knobs on sensor or laser loose
›› Temperature changing: machines recently shut down?
›› Uneven shaft rotation
›› Shaft deflections from coupling strain
93
5.14 Saving data and printing
Before switching off the OPTALIGN smart computer, dimensions, measurements,

results and all settings can be saved for analysis, future use or record purposes in
the computer’s non-volatile memory. Full file names with up to 32 alphanumeric
characters are possible.
The length of the file name is limited depending on the typeface used.
5.14.1 To save a file

H
Note
The current measurement file can be saved at any time. To save the file, press q
twice. Highlight ‘Save file’ using f/g.
Press e to confirm selection. The editing box appears.

94
When entering names that

contain both upper and lower
case characters as well as
numerals, use o to cycle
through the three options.
Press and hold down o while
observing the status indicator at
the top left corner of the editing
box. This displays the type of
character to be entered.
Empty spaces are entered by
pressing 0.
Use the data entry keys to enter the file name and confirm entry by pressing either
ß or e.
Saving and printing
5.14.2 Printing reports

Using the default printer type ‘PDF file’, measurement reports may be saved as a PDF
to the approved memory stick ALI 17.451 then printed off any Windows printer or
network printer without disconnecting or reconfiguring the printer.
Reports can also be printed directly from the OPTALIGN smart computer to a printer.
To print the current measurement report, press q twice, then use f/g to
highlight ‘Print’.
Press e to confirm selection. The “Print report” screen appears.
Note: As may be seen

from the screen header,
the selected printer type 95
is the default – ‘PDF file’.
In this case, the report will
be saved as a PDF on the
approved memory stick.
The system provides the option of printing reports in four different formats. Use
f/g to highlight the desired format and then press e to print the selected
report.
5.14.3 Configuring printer

If it is desired to print the report directly from the system, the printer settings must be
set accordingly. This can be carried out from the “Print report” screen. Press q and
use either f/g to highlight the context menu item ‘Printer configuration’.
Press e to confirm selection. The “Printer configuration” screen opens and the
printing settings are made. The settings may also be verified if unable to print meas-
urement report.
Alternatively, the “Printer configuration” screen may be accessed at any time as
described in section 8.2.6 ‘Printer configuration’.
5.14.4 Available printing options

The “Printer configuration” screen shows the options that can be selected.
96
Note: Currently set printer

type is the default – ‘PDF
file’.
Use either f/g to highlight the printer setting to be changed. The options
that are available are displayed by pressing e.
Saving and printing
Use f/g to scroll

through the available
printers. Highlight a printer
and press e to confirm
selection or use ß to exit
the selection box.
The top-most printer type [in this case the default printer type – ‘PDF file’ – may be
selected by pressing 0.
Use f/g to scroll

through the available paper
sizes. Highlight the required
paper size and press e
to confirm selection or use
ß to exit the selection
box.
97
Use f/g to
change the page orientation
between ‘Portrait’ for
a vertical layout and
‘Landscape’ for a horizontal
layout. Confirm selection by
pressing e or use ß to
exit the selection box.
Use f/g to
select the colour in which
the report will be printed.
Selecting ‘Colour’ results
in full colour reports, while
‘GrayScale’ results in black
and white reports.
98
Quick check
5.15 Quick check measurement
At some point, it may be necessary to check the alignment of a machine set that
has been running long enough to reach its ‘steady state’ (‘hot’) operating condition.
In that case, the system can be used to take quick alignment readings in a matter
of a few minutes after the machines are shut off. The following procedure saves
time by allowing the user to begin measurement immediately after switching on the
computer and not entering machine dimensions first.
1. As soon as the shafts have stopped rotating, lock out machines and observe
all safety precautions, then mount the components as described on section 5.4
[‘Mount laser and RS5 BT sensor’].
2. Switch both the OPTALIGN smart computer and the RS5 BT sensor on, then
press m to establish wireless communication between the computer and the
sensor [for details refer to section 5.9.1]. If the laser beam has been centered
on the detector, turn the shafts in their normal direction of operation by at least
70°.
If however measurement
is finished by pressing
99
e, then pressing the

the results key k to
view foot results, a hint
screen appears requesting
3. After rotating the shaft by at least 70°, press the results key k. The missing dimensions to be
“Dimensions” screen with missing dimensions opens. entered.
OPTALIGN smart RS5 handbook
4. Proceed to enter the required dimensions.
Missing dimensions are

entered using the data
entry keys and confirmed by
pressing e.
100 5. Once all dimensions have been entered, the results screen appears.
The alignment results If however, the option

displayed depend on ‘All-in-one results’ has
whether the shaft setting not been activated
‘All-in-one results’ has in the ‘Shaft settings’
been activated. The screen configuration menu, only
opposite shows both the the sensor to coupling
coupling and feet results. center dimension needs
Use k/f/g to to be entered to display
cycle through the different coupling results.
results views.
Soft foot
5.16 Soft foot
Soft foot is the condition of machine frame distortion. Any cause that results in
machine frame distortion when the machine is anchored to its foundation is a soft
foot. Some of the principal causes are:
›› Non-coplanar machine mounting surfaces,

›› Deformed machine frame or feet,
›› External forces e.g. from connecting pipe or bracket,
›› Improper shimming or soiled machine feet.
›› Too many shims under a machine foot (a maximum of 3 should be used)
The consequences of forcibly tightening down the feet are deformed machine
frames, bent shafts and distorted bearings. This leads to high vibration and premature
failure.
Soft foot should be checked before aligning the shafts. This can be done quickly and
conveniently with the aid of the instrument’s soft foot function. With the sensor and
laser mounted on the shaft at any angular position, the system is able to sense any
machine movement when the machine bolts are loosened individually. By entering the
machine dimensions, the system is able to calculate, from shaft movement, by how
much each foot has moved as it is loosened.
101
Parallel soft foot Angular soft foot
One or more feet are The base of the foot is at
too short or too long. an angle to its foundation
This usually results in the and they are only partly in
machine rocking on the contact. In this case, suspect
longer feet. This is corrected foot is checked with a feeler
by shimming the shorter gauge and corrected by
feet. building a custom ‘shim
wedge’ or machining the
underside of the foot.
Once foot movements have been established, the results are interpreted and
translated into shim thicknesses to be placed under the feet. How straightforward
this is, depends on the type of soft foot present.
5.17 Checking and correcting soft foot conditions
The three main types are parallel soft foot, angular soft foot, and induced soft foot.
There are instances where the soft foot is a combination of two or more types.
Checking for soft foot is part of machine and job preparation.
H
The machine to be checked is assumed to have four feet which are bolted down
in an approximately square formation. If the machine has six feet, it is advisable
Note
to leave the middle feet loose and treat the machine as a four-footed machine.
Soft foot is measured only on machine designated as movable.
1. Set up the system in the normal way as described in sections 5.3 – 5.4, then
switch the laser on. Adjust the beam onto center of the sensor dust cap.
2. Switch the RS5 BT sensor on then open its aperture by lifting and rotating the
sensor dust cap to its “open” position.
3. Switch the OPTALIGN smart computer on then enter machine dimensions.
4. Use the navigation keys to highlight machine whose feet are to be measured.
5. With the machine highlighted, press q. The context menu appears.
The soft foot icon may be

used to directly access the
soft foot measurement
102
screen.
6. Use f/g to highlight the context menu item ‘Soft foot measurement’
then press e to confirm selection. The “Soft foot” screen may also be
accessed by using the navigation keys to highlight , then pressing e to
confirm selection.
Soft foot
7. If the laser beam is centered, the following “Soft foot” screen appears.
8. Press e to continue with soft foot measurement ( proceed to step 8f).

If however, the laser beam is not centered, the following “Soft foot” screen
appears.
103
8a. Use the on-screen instructions to adjust the laser beam, or refer to section 5.9
‘Laser beam adjustment’.
8b. The laser beam can also be centered using the XY view. Access the XY view
screen by pressing q while in the soft foot screen. The context menu appears.
The context menu item

‘Adjust laser’ may also
be used to prompt the
on-screen instructions. With
the context menu displayed,
use either f/g
to highlight the context
menu item ‘Adjust laser’,
then press e to confirm
selection.
8c. With context menu item ‘XY view’ highlighted, press Full description of ‘XY
e to access the “XY view” screen. View’ may be found in
section 6.2.5.
104
8d. Use the adjustment thumbwheels to center the laser beam. Use the top
thumbwheel to move the beam up/down. The side thumbwheel is used to move
the beam sideways.
Soft foot
8e. After centering the laser beam, press ß to return to the soft foot screen. Press
e to proceed with measurement.
If however, either of the two significant machine dimensions, ‘front foot-to-back

foot’ and ‘sensor-to-coupling center’, are missing, the following hint appears.
H
Note
Use f/g to
highlight ‘Yes’, confirming
selection by pressing e.
The dimensions screen
opens, and missing values
may be entered.
8f. After all required dimensions have been entered, the soft foot screen opens
automatically. Proceed with soft foot measurement.
9. Use the navigation keys to select the foot to be measured. Press e to confirm
foot selection. Loosen the corresponding anchor bolt.
105
10. The calculated distance that the foot has moved is shown on the screen. Press
e to store the value and retain it in the display. Retighten the bolt. The next
foot is highlighted automatically, or any desired foot can be selected using the
navigation keys.
11. Repeat this procedure for each foot. Cycle through using the navigation keys if
required.
The set soft foot tolerance

is 0.06 mm (0.002”). The
happy Smiley indicates that
the measured soft foot
is within tolerance and
shimming corrections are
not necessary.
With the four foot values, the shimming corrections can be determined. Note that
these values are saved in the file along with the dimensions, measurement and results,
and appear in the printed report.
The “Soft foot” screen context menu items may be used to carry out the displayed
functions.
The context menu items

‘Clear all SF measurements’
and ‘Pipe strain wizard’
toggle depending on
whether soft foot values are
available or not.
106
Soft foot
5.17.1 Parallel soft foot correction

If two diagonal values are roughly equal and significantly higher than the other two,
parallel soft foot can be assumed as a first solution.
5.17.2 Angular soft foot correction

If one value is significantly higher than the others, then angular soft foot can be
suspected.
The ‘problem foot’ or machine frame is probably bent or distorted in some way. In
this case loosen the bolt and examine the foot more closely. Use a feeler gauge to
establish the variation of the gap and use these measurements to sketch the shape
and dimensions for a ‘stair stepped shim wedge’.
If the soft foot is purely ‘angular’ then the stepped shim will vary in thickness from
about zero to twice the value displayed by the computer.
Parallel soft foot

The machine is rocking on
two diagonal feet which
are longer than the other
two. In this example, the Angular soft foot
correction would be to The base of one or more
place a 0.89mm shim under feet is at an angle to the
foot ‘b‘ (the foot with the foundation and is only
largest gap) partly in contact.
107
a 0.18 0.89 b a 0.18 0.13 b
c 0.74 0.10 d c 0.76 0.10 d

5.18 Checking pipe strain

The effects of pipe strain on shaft alignment can be measured using the system.
This feature is used to check for strain from external sources acting on machines.
The measured values are quantified in terms of offset and angularity. The values are
combined for both the vertical and horizontal directions. This check can prove the
existence of pipe strain on a pump or conduit strain on a motor.
An external stress on a machine frame usually results in machine frame distortion. It is
important to ascertain its existence and eliminate it. This check complements but does
not replace the soft foot function.
5.18.1 How the function works

After mounting the laser and sensor with integrated Bluetooth as usual (refer
to sections 5.3 – 5.4), turn the system computer on. Enter all necessary machine
dimensions as usual. Press q while in the dimensions screen. The context menu with
the function ‘Pipe strain wizard’ appears.
108
With the context menu displayed, use f/g and highlight ‘Pipe strain wizard’
then press e to confirm selection. The wizard starts.
The wizard opens always

with the ‘Next’ button
highlighted. Should this
not be the case, use the
navigation keys to highlight
‘Next’. The wizard may be
exited by highlighting the
‘Exit’ button and confirming
Pipe strain
With the ‘Next’ button highlighted, press e to proceed.
If the components have not yet been mounted, ensure that they are properly
mounted. Make sure that both the sensor with integrated Bluetooth and the
laser are switched on. You may refer to sections 5.4.
H Note
With the ‘Next’ button highlighted, press e to proceed with measurement. The
measurement screen appears.
If the laser beam is not

q
centered, press
then use g/f
to highlight the context
menu item ‘Adjust laser’,
confirming selection 109
by pressing e. After
adjusting the laser
beam press e or
ß to proceed with
measurement.
Rotate the shafts over a wide enough measurement range. When a wide enough
measurement range is attained, the ‘Stop’ button appears.
With the ‘Stop’ button highlighted, press e to finish the first measurement. The
instruction to loosen pipe flange bolts then appears.
110
After loosening the pipe flange bolts, press e with the ‘Next’ button highlighted.
This prompts the start of the second measurement step.
Pipe strain
Proceed to take measurements as described in first measurement steps previously.
Pipe strain results are automatically displayed after pressing e with the ‘Stop’
button highlighted.
Toggle between ‘Finish’ and

‘Print’ using the navigation
keys. Confirm required
option by pressing e.
111
The pipe strain measurement is documented in the file measurement report and may
also be saved as an individual pipe strain measurement report PDF file or printed
directly from the system computer. To save or print report, refer to section 5.14
‘Saving data and printing’.
The measurement procedure and wizard instructions are dependent on the

measurement mode used. In all instances, a wide enough measurement range
has to be attained.
H
Note
112
Measurement modes
Chapter 6: Alignment features
6.1 Measurement modes
In addition to the standard ‘Continuous Sweep mode’, the system also offers
Multipoint and Static measurement modes.
The measurement modes are accessed via the measurement screen. Press m to
access the measurement screen. While in the “Measurement” screen, press q.
Use the navigation keys to select ‘Measurement mode’ -> ‘Multipoint’ (or ‘Static’ or
‘Sweep’). The choice depends on the measurement mode required.
Note: The default The default measurement

measurement mode may mode is effective only
be set via the Configura- when a new file is
tion menu item ‘Default opened. Auto-resumed
settings’. Changing the files are opened with the
measurement mode from last used measurement
the “Measurement” screen mode.
does not change the set
default mode but changes
only the measurement
mode used within the
opened measurement file.
113
In this case, the selected
measurement mode,
Multipoint is now active.
6.1.1 Multipoint measurement

Note: To be able to carry
This mode is used to measure shafts which are either difficult to turn continuously
out measurements using
or allow measurement only in certain rotational positions. The method can also be
Multipoint measurement
used to measure uncoupled shafts, nonrotatable shafts, sleeve bearings, white metal
mode, an optional
bearings and journal (radial) bearings.
firmware module is
necessary. Please order
After centering the laser beam as described in section 5.9 ‘Laser beam adjustment’,
press e to take the first measurement point. Rotate shafts in their normal direction
[Multipoint] to activate
of operation from one measurement position to the next, pressing e to take
this feature.
measurement. Measurements must be taken in at least three positions over at least
70° of rotation, but more measurements over a wider angle is recommended.
The measurement arc

turns from red to yellow
to green depending on
the number points taken
and the angle covered. A
yellow arc signifies that the
taken measurements are
the minimum required to
obtain results; however, it is
recommended to obtain a
green arc for even greater
accuracy and quality of
After finishing measurement, press k to display readings.
results.
114
6.1.2 Static measurement

This measurement mode is used for vertical foot-mounted or flange-mounted
machines, uncoupled shafts, and nonrotatable shafts.
After centering the laser beam as described in section 5.9 ‘Laser beam adjustment’,
turn the shafts to any of the eight 45° positions (i.e. 12.00, 1.30, 3.00, 4.30, 6.00,
7.30, 9.00 or 10.30 o’clock positions viewed from coupling towards laser emitter).
Position shaft as accurately as possible using either an external inclinometer, spirit For horizontally oriented
level or protractor. shafts, the optional
external inclinometer
Use the navigation keys to position the clock hour hand to the corresponding shaft ALI 5.020 may be used.
position.
Measurement modes
Pressing the navigation

keys positions the clock
hour hand at the next 45°
position.
Press e to take the first measurement point. After point is taken, rotate shafts to the
next measurement position. Ensure shafts are accurately placed at the 45° position.
Use the navigation keys to move the clock hour hand (red cursor line) on the display
screen to the corresponding shaft position. Take next measurement point by pressing
e.
If shaft rotation restrictions hinder the taking of measurement at particular shaft

positions, bypass these using the navigation keys.
H
Note
Measurements must be taken in at least three positions over 90°, but it is recommended
to take more measurements over a wider angle. Eight is the maximum number of
points that may be taken over 360°.
115
After finishing measurement, press k to display results.

6.2 Distinct measurement features
6.2.1 Extending the measurement range

Gross misalignment of shafts or small angular misalignment over large distances can
cause the laser beam to miss the detector surface during measurement. When this
happens, ‘Laser end’ appears on the display screen and the instrument’s ‘Infinirange’
function can be used.
H
The ‘Infinirange’ option is available only in ‘Multipoint’ and ‘Static’ measurement
modes.
‘Laser end’ is displayed when the laser beam falls out of the detector’s useful Note
linearized measurement range. ‘Laser off’ is displayed if the beam is blocked or
falls entirely outside the detector area. This situation occurs when machines are
severely misaligned, or when the beam travel is long. Measurement is not taken
when this message appears.
1. When measuring and ‘Laser end’ message appears, rotate the shafts backwards
until the laser beam re-enters the measurement range. The message ‘Laser
OK’ reappears on the display. Press q to access the ‘Infinirange’ option. Use
g/f to highlight ‘InfiniRange’.
116
2. Press e to confirm selection. The program interrupts measurement and

switches to the beam adjustment screen. The current beam position is automati-
cally recorded and taken as the starting point for range extension.
Extend measurement range
CAUTION! Do not allow

shafts to turn during this
process.
3. Readjust the beam into the target circle using the yellow laser emitter
adjustment thumbwheels.
117
4. On centering the laser dot, the blue system computer LED lights up. Press e.
The adjusted beam position is automatically recorded and taken as the end point
of the readjustment.
5. Continue measurement as before, rotating the shafts and pressing e to take Note: The ‘Infinirange’
measurements at the desired positions. beam readjustment
procedure (steps 1 – 5)
The program includes the displacement of beam readjustment in its alignment cal- may be repeated as often
culations. as necessary to obtain
sufficient measurement
6.2.2 Remeasuring points or rotational arc to
The possibility to remeasure is provided in all measurement modes. To remeasure, complete a set of readings
the current measurement needs to be stopped. To stop a measurement, press q successfully. This allows
while carrying out measurement. Use g/f to highlight the context menu item even very gross misalign-
‘Stop’. ment or very long spans
across spacer shafts to be
handled with ease.
Note that the context menu

item ‘Stop’ is available only
after a measurement has
been started.
Confirm selection by pressing e.

To start a new measurement, press q and use g/f to highlight the context
118
menu item ‘Start’.
The context menu item Note: The context menu

‘Start’ is available only item ‘Measurement
before a measurement is details’ which may also be
started. accessed via the “Results
table” context menu
appears only when the
measurement is valid.
Resume/Averaging
A different measurement mode can also be selected under ‘Measurement mode’

before starting to remeasure.
6.2.3 Resume
The system provides the possibility to turn off the computer during measurement and
resume with the last file opened. On switching the computer on, the measurement
file loaded is the one that was last opened, provided it had already been saved. If you
prefer to open a completely new file, use the context menu item ‘New file’ which
is accessible from any screen. The ‘Resume last file’ action is possible only from the
dimensions screen
This auto-resume function ensures that the measurement file last selected, when the
instrument switches itself off due to the power management function ‘power scheme’ 119
(see section 8.2.1 ‘Device settings’), remains the active file when the instrument is
switched on again.
6.2.4 Averaging
In certain industrial conditions, it may be necessary to increase the number of
measurements to be averaged when taking readings to attain the desired accuracy.
Particular cases include applications with increased machinery vibration. An increased
averaging also improves the accuracy when measuring sleeve bearings, white metal
bearings and journal bearings.
The number of individual readings which are averaged together to form one
measurement are set via the measurement screen. Press q while in the measurement
screen. Use g/f to highlight ‘Averaging’.
120
The average setting can be changed from a minimum averaging of 0.5 seconds to a
maximum averaging of 10.0 seconds.
H
Averaging is possible only in Multipoint and Static measurement modes. The
averaging setting that is selected will also be active in soft foot and Move. Should
high averaging be selected, patience must be exercised during Move to allow the
Note
system enough time to ‘catch-up’ as the machine is moved. In this case, each
reading that must be calculated to update the graphic display will take a longer
time. Averaging cannot be changed once a measurement has been started.
XY View
6.2.5 XY View
Before measurement begins, the laser beam must be adjusted such that it strikes
the detector surface. The beam should strike the detector as close to the center as
possible. To facilitate adjustment, the height of the sensor and the laser should be
aligned, and the brackets are rotationally aligned.
The option ‘XY View’ can be activated to help meet the requirement mentioned
above.
q while in the measurement screen. Use
To access the “XY View” screen, press
g/f to highlight the context menu item ‘XY View’.
Confirm selection by pressing e. The laser beam position on the two detector
planes is displayed.
Displayed are the absolute

X,Y coordinates of the laser
121
beam on the two detector

surfaces, the angle at which
the sensor is currently
positioned on the shaft and
the sensor temperature.
Additional ‘XY View’ capabilities include the setting of the XY coordinates as a

reference value. To access this option, press q while in the “XY View” screen above.
Use g/f to highlight ‘Relative coordinates’. Pressing e to confirm selection

sets the current laser dot position at 0,0 on both detectors.
The adjusted beam position

is set to ‘0,0‘ on both
detectors to serve as a
reference.
Press e to toggle
between the reference and
the absolute values. This can
also be done via the “XY
View” screen context menu
item ‘Absolute coordinates’.
122
If the laser beam dot is adjusted while in the “Relative mode” screen, it traces a path
showing the laser dot movement:
The new absolute positions

are ‘0.3, -2.5’ and
‘0.5, -6.4’.
Machine train alignment
Chapter 7: Special alignment applications

This chapter deals with alignment of machines that require use of special procedures
rather than those for the standard horizontal alignment. These special applications
include:
Machine trains (groups of three machines coupled together)
Cardan drive machines
Flanged machines (mounted vertically or horizontally)
7.1 Machine train alignment Note: To measure the

alignment condition of
7.1.1 How to align machinery trains three-machine trains, an
The following step-by-step approach is recommended for three-machine trains. optional firmware module
1. Measure alignment at each coupling is necessary. Please order
2. Display results and optimize corrections (by defining ‘stationary’ machine feet) part number ALI 12.723
3. Align two machines (remount laser and sensor if necessary) [3-Machine Train] to
4. Recheck alignment results activate this feature.
5. Align the two machines at the next coupling and repeat alignment check
7.1.2 Machine train set-up

Machine train set-up resembles the set-up described in section 5.7 and will therefore
be outlined here only briefly.
1. While in dimensions screen, use the navigation keys to highlight either machine
then press q. The context menu with the menu item ‘Add last machine’
appears.
123
2. Use f/g to highlight “Add last machine” and confirm selection by

pressing e. The added machine appears on the right end of the train.
3. Configure the machine train as appropriate.
The train elements

appearing on the screen are
shown highlighted on the
train icon at the top right of
the display. Pressing h or
i long enough moves the
view of the train to the right
or left respectively.
124
Use h/i to highlight
machine to be edited.
Pressing e reveals the
corresponding submenu.
7.1.3 Measurement
1. Use h/i to select the coupling to be measured.
2. Ensure the laser is mounted on the left side of the selected coupling.
3. Remove the dust cap from the laser and switch it on. Leave the sensor dust cap
on.
4. Press m and adjust the beam onto the sensor (refer to section 5.9 ‘Laser beam
adjustment’).
5. Proceed to carry out measurement as described in section 5.10 ‘Take measure-
ments’, observing the requirements for valid measurement — shafts must be
rotated by at least 70°; a minimum of 3 measurement points to be taken.
In this example, coupling

1 is measured using the
Multipoint measurement
mode. Measurement is
q
stopped by pressing
then using f/g to
highlight the context menu
‘Stop’. Press e to confirm
selection.
6. If using Continuous Sweep measurement mode, press e to stop measurement.

If the measurement mode used is not Continuous Sweep, measurement is
stopped by pressing q then using f/g to highlight the context menu
item ‘Stop’, and confirming selection by pressing e. 125
Pressing e with the

context item ‘Stop’ high-
lighted stops measurement.
7. Mount the laser and sensor across the next coupling.

8. While in the “Measurement” screen, press h/i long enough to move to the
next coupling to be measured.
In this example, coupling

2 is measured using
the Continuous Sweep
measurement mode. In
this case, measurement is
stopped by pressing e.
H
Please make sure when moving the laser and sensor to each coupling that the
dimension from coupling center to sensor is entered correctly in the dimensions
screen, since you might not replace the sensor bracket in exactly the same Note
location each time.
Always make sure the coupling you are measuring is the one actually highlighted
in the machine train.
9. Repeat the measurement procedure as described previously at the second

coupling position.
126 7.1.4 Evaluating results

Press k to view the alignment results at the individual couplings. Cycle through all
available results screens using f/g/k.
Horizontal and vertical

feet and coupling values
for machines A and B. In
this example, the option
‘All-in-one results’ is
activated in the ‘Shaft
settings’ configuration
menu. If not activated then
the screen displays only
coupling results.
Vertical feet and coupling

values at the coupling
position between machines
A and B
Horizontal feet and coupling

A and B
Entire machine train

overview with vertical
127
between machines A and B

overview with horizontal
between machines A and B
Press and hold i/h to jump to the next coupling in the train.
Jumping from one coupling position to the next is carried out from results screen
depicting two machines only. When in the results overview screen, jumping from
one coupling to the next is possible only when the cursor is on either foot postion
H
Note
of the middle machine.
Vertical and horizontal feet,

and coupling values at the
coupling position between
machines B and C
128
Vertical feet and coupling

B and C
Horizontal feet and coupling

B and C

overview with vertical
between machines B and C

overview with horizontal
129
between machines B and C
7.1.5 Move corrections

After deciding on which pair of machines to move in a train, one may need to reinstall Machine pair to be
and readjust the laser and sensor across the chosen coupling. Be sure to install the moved can be selected in
sensor at exactly the same location on the shaft or coupling as previously, or reenter “Dimensions” or “Results”
the new correct distance from the sensor to the coupling. screens by pressing h/i
Correction of misalignment may be carried out using the Live Move function. While in long enough.
results screen, highlight the machines to be moved then press q. The context menu
appears. Use f/g to highlight ‘Move’.
Confirm selection by pressing e. If the laser beam is centered, and either machine
is designated stationary, Live Move starts automatically.
130
If however, the pair of machines selected are both designated movable, then a hint
appears on the display requesting the designation of only one machine as movable.
If the laser beam has not

been centered, the laser
adjustment guide appears
on the screen. Use it to
center the laser beam
Use f/g to highlight the machine to be moved, then press e to confirm

selection. If the laser beam is centered, Live Move starts automatically.
Do NOT attempt to move the machine using heavy sledgehammer blows. This
can cause bearing damage, and also produce inaccurate Live Move results. Jack
bolts on the feet or other mechanical or hydraulic devices are recommended for
a
CAUTION
moving machines.
131
Move the machines until the alignment condition is within the specified tolerance
which is indicated by the smiley and the system computer alignment condition LEDs.
Tighten the anchor bolts and then press q to conclude the Move procedure. The
Live Move context menu appears. Use f/g to highlight ‘Stop’.
Press e to finish Live Move. A hint appears on the display requesting whether to
repeat move or exit and remeasure.
Use f/g to
highlight action to be
taken. Press e to confirm
selection.
H
132
As the true position of shaft rotation axes can only be determined by rotating the
shafts during measurement, it is not possible to exit Live Move without carrying
Note
out another measurement.
Remeasure to confirm the alignment condition. If the smiley returns a happy face, the
alignment condition is within tolerance and you may press e to save measurement
results.
7.2 Cardan drive machines
This section describes the aligning of cardan shafts using the cardan shaft bracket lite
ALI 2.874 SET iS used in conjunction with OPTALIGN smart RS5 BT system. Cardan
drives are installed and operate with a large offset between the driver and the driven
shaft. The cardan shaft is set at a considerable angle (usually 4° to 6°) in order to
ensure sufficient lubricant circulation, which in turn prevents the universal joints from
seizing. Excessive misalignment of such a configuration leads to rapid fluctuation of
the driven shaft RPM during operation, which holds grave consequences for electron-
ically-controlled synchronous and asynchronous AC drive motors.
Precise alignment reduces the rotational irregularities of the cardan shaft to a minimum,
so that the uneven bearing loading during cardan shaft rotation is also minimized, the
service life of the components is extended and the chance of unexpected machine
failure is reduced.
The measurement procedure described here allows precise measurement of machines
joined by cardan shafts over distances of up to 3 m (10 ft) and shaft offsets of up to
400 mm (15 3/4 in).
7.2.1 Mounting the faceplate to the rail

1. Slide the the faceplate down the rail as shown in 1 below. The four T-nuts
should sit in the grooves.
2. After positioning the faceplate on the rail, tighten the four socket head screws
using the provided M5 allen key [ 2 ].
133
1 2
3. Mount the bracket assembly to the coupling face of the non-rotatable shaft. If
the coupling face has a raised rim, the precision machined spacers are used as
shown [ 3 ] in order to separate the bracket faceplate from the coupling face.
The coupling shown

opposite has a raised
face flange. The provided
spacers are used to create
a three-point plane to
ensure that the faceplate
and the coupling face,
3 which is the reference
surface are joined
Reference surface
together.
(Without the spacers, there would be no direct contact between the faceplate and the
coupling surface surrounding the bolt holes – exactly the location where the faceplate
and coupling are being joined.)
The center part of the coupling face must not be used as a reference surface.
H Note
7.2.2 Mounting the laser holder assembly on to the rail

1. Loosen the handwheel slightly, then slide the laser holder assembly down the
center groove of the rail, with the T-nut acting as a guide [ 1 ].
134
RS5 laser holder
1
7.2.3 Mounting and adjusting the RS5 laser

In this step, the laser beam is adjusted such that it is roughly colinear to the rotational
axis of the laser holder assembly.
1. Slide the two black distance sleeves down the support posts.
2. Slide the RS5 laser onto the posts until it rests on the distance sleeves [ 2 ].
3. Mark a set of target crosshairs on the shaft rotation centerline of the other
machine coupling (if the flange has a center hole, a temporary target surface
may be affixed to the hole).
4. Switch on the RS5 laser and adjust the beam to strike the center of the target on
the opposite coupling:
›› The objective is to adjust the laser beam such that it is roughly colinear to the
rotational axis of the laser holder assembly; this will make it possible to make
fine adjustments to the laser holder assembly’s position afterwards, without
having to realign the laser beam itself.
The distance sleeves (black) influence the offset by positioning the laser beam on
the same axis as the rotational axis of the laser holder assembly. H
Note
›› The two yellow beam position thumbwheels are used to adjust the angular
position of the laser beam. By rotating the laser assembly holder, the laser
beam traces an ‘approximate’ circle. If the ‘approximate’ circle is a single dot
at the center of the target, then the laser beam has been adjusted correctly.
If that is not the case, repeat the laser beam adjustment process until the
‘approximate’ circle corresponds to a single dot position.
135
Distance sleeve
(black)
RS5 laser adjustment tip:
H
If the beam describes a circle rather than a dot at the target when rotating
the laser holder assembly, then note how big the circle is and use the yellow
adjustment thumbwheels to move the laser beam back by half the distance it
Note
has moved when rotating the laser holder assembly 180° from its start position.
Do this both vertically and horizontally. When correctly adjusted, you should be
able to rotate the laser holder assembly a full 360° without the laser dot moving
from the target center.
As soon as a single dot position has been achieved, do not touch the laser
position thumbwheels. H
Note
136
7.2.4 Adjusting the RS5 laser beam to machine’s rotational axis

In this step, the laser holder assembly is adjusted on the bracket such that the laser
holder rotational axis is colinear with the rotational axis of machine to be aligned
(which could be a motor or a gearbox).
During this procedure, DO NOT touch the yellow laser beam position
thumbwheels.
H
Note
1. Carry out the vertical and horizontal adjustment of the laser holder assembly
by sliding it horizontally through the bracket rails and positioning it vertically by
rotating the bracket (see 1 below).
2. Repeat the above procedure until the laser beam strikes the center of the target
placed on the rotational axis of machine to be aligned.
3. Once the laser beam has been centered on the target, tighten the faceplate on
the coupling face using the provided hexagon socket head screws.
7.2.5 Positioning RS5 laser and mounting RS5 BT sensor for measurement
In this step, the RS5 laser is remounted on the underside of the laser holder while the
RS5 BT sensor is mounted on the shaft of the machine to be aligned.
1. Switch off the RS5 laser then remove it from its holder.
2. Using the provided M4 Allen key, loosen the support posts then slide them
through the laser holder base so that they protrude from the other side (see 2
below).
3. Retighten the M4 Allen screws to secure the support posts, then remount the
RS5 laser onto the support posts.
137
Laser dot
1
4. Use the chain-type bracket or appropriate magnetic brackets to mount the RS5
BT sensor ALI 3.901 on the shaft of the machine to be moved (for instance the
motor or gearbox) – (see 3 below).
5. Switch the RS5 laser on. The sensor is aligned to the laser by pushing or sliding
the bracket supporting the sensor (see 3 below).
Do not touch the RS5 laser or its laser position thumbwheels.
7.2.6 Set-up and measurement

H Note
1. Switch the OPTALIGN smart computer on, and then proceed to set up the
machines (refer to ‘Machine set-up’ section 5.7). Select ‘Change to cardan’ in
coupling properties (refer to ‘Coupling properties’ section 5.7.4).
2. Enter all required machine dimensions.
Note: The cardan

shaft coupling type is
an optional firmware
module. Please order
[Spacer shaft] to activate
the feature.
138
3
3. With the sensor aperture open, press m and establish wireless communication
(refer to ‘Wireless measurement’ section 4.4’). The laser beam location should be
apparent in the adjustment screen.
4. Press q. A context menu appears. Use the context menu item ‘Measurement
mode’ to select the ‘Multipoint’ measurement mode. (For details about this
mode refer to ‘Multipoint measurement’ section 6.1.1.)
Note: The Multipoint

measurement mode is
an optional firmware
module. Please order
[Multipoint measure
mode] to activate the
feature.
5. Press e to confirm selection.

6. The laser dot should be in the square target. If not, center laser beam (refer to
‘Laser beam adjustment’ in section 5.9).
139
7. With laser beam centered, press e to take the first measurement point.
8. Rotate the sensor to the next measurement point.
9. Rotate the laser holder and the RS5 laser and observe the detector view in the
measurement screen (see next screenshot): at the moment when the laser dot is
positioned on the Y-axis, press e to take the next measurement.
10. Repeat steps 8 and 9 to take measurements in at least three positions over at
least 70° of rotation. (Taking more position measurements improves the reliability
of results.)
11. When enough measurement points over at least 70° rotation have been taken,
Alternatively, stop
press q then use f/g to highlight the context menu item ‘Stop’.
measurement by pressing
Confirm selection by pressing e to stop measurement.
q followed by 3.
140
7.2.5 Evaluation and alignment

Since offset does not affect the performance of cardan shafts, only angularity is
displayed for correction.
1. Press k to view alignment results.
Note that the angularity

is displayed in degrees
or mrad depending on
the ‘Angle format units’
selected under ‘Shaft
settings’ in the ‘Con-
figuration’ menu (refer to
section 8.2.7).
2. Cycle through the feet results using k/f/g. If a specific amount

of offset between the
machine shafts was
desired and the laser
holder assembly was set
up to this precise offset
as described in step 2
(section 7.2.2) previously,
then, after the angular
alignment of the movable
machine is completed,
remount and readjust
the laser as described in
steps 1–5 (section 7.2.3)
and proceed to adjust 141
the movable machine in
a parallel manner both
vertically and horizontally
until the beam spot hits
the movable machine
shaft‘s centerline of
rotation, taking care not
to change its angular
alignment.
3. If the machines are out of tolerance, reposition them with the help of the Move
function (refer to sections 5.13.3 – 5.13.5).
4. Remeasure to determine the new alignment condition.
7.3 Vertical and horizontal flanged machines
A typical vertical machine arrangement comprises one machine mounted on top of

the other using a bolted flange.
Flange-mounted machines can be situated vertically or horizontally. In either case,
alignment corrections are made directly at the flange.
Angularity is corrected by inserting or removing shims between the flanges. The
system calculates the shimming thickness for each flange bolt. Offset is corrected by
positioning the flange laterally.
7.3.1 Set-up
Before commencing with this section, please acquaint yourself with chapter 5
‘Horizontal machine alignment’.
H
Note
The RS5 laser and RS5 BT sensor are mounted on either side of the coupling as with
horizontal machines, with the laser on the shaft of the machine designated stationary.
The electronic inclinometer cannot determine the rotation angle of vertical shafts;
therefore, on vertically oriented machines, measurements must be taken using Static
measurement mode. The eight 45° measurement positions used with this procedure
must be marked accordingly on the machine.
7.3.2 Marking measurement positions

1. Mark a reference position on the bearing housing close to the shaft and in line
with one of the pillars or bolts. Likewise, mark a starting point on the shaft. This
ensures that lateral corrections can be performed with the minimum of effort.
142
2. Measure the circumference of the shaft and divide by eight.
3. Use this distance to make seven more evenly-spaced marks on the shaft
beginning at your chosen start point. Number the points counterclockwise as
seen from laser to sensor, beginning with 0 first, followed by 1:30, 3:00, 4:30,
6:00, 7:30, 9:00 and 10:30.
The shaft is numbered

counterclockwise looking
down the shaft, starting 0:00 4:30
at 0 followed by the clock 1:30 3:00
positions 1:30, 3:00, 4:30,

6:00, 7:30, 9:00 and 10:30.
Vertical flanged machines
For circular housings, measure the circumference of the bearing housing and divide by
eight. Use this distance to make eight evenly-spaced marks on the housing
beginning at your chosen start point. Number the points clockwise looking 0:00 10:30
down onto the shaft with 0 as the first, followed by 1:30, 3:00, 4:30, 6:00, 1:30 9:00
7:30, 9:00 and 10:30. (Refer to the diagram opposite.)
7.3.3 Mounting components and selecting machine orientation

1. Mount the sensor with the integrated Bluetooth, and the laser on either
side of the coupling, ensuring that they are aligned exactly with the 0 or
reference mark.
2. Switch OPTALIGN smart computer on by pressing e.
3. From the dimension screen that appears, press q. With the context
menu displayed, use the navigation keys to highlight ‘Train orientation’ >
‘Vertical train’.
143
4. Confirm selected train orientation by pressing e. A hint appears requiring the

acknowledgement of the change. Use f/g and highlight ‘Yes’ and then
press e to acknowledge change.
7.3.4 Editing flange configuration

A typical vertical machine train arrangement consists of machines mounted together
using a bolted flange. To configure the flange proceed as follows:
1. With MTBM highlighted press e then use g to highlight “Change to
flange”.
2. Confirm selection by pressing e. The “Edit flange” screen appears.
The parameters that can be

edited are number of bolts,
outer flange and bolt circle
diameters. These parameters
are highlighted using the
navigation keys, and edited
directly using the data entry
keys.
144 3. To edit the flange pattern, press q while in the ‘Flange edit’ screen. Use the
menu items ‘Flange shape’ and ‘Predefined bolt settings’ to edit the flange.
The following flange patterns are available:
›› Circular flange
›› Square flange – circular bolt pattern
›› Square flange
4. Highlight the menu item ‘Flange shape’ using g/f. This displays the
flange pattern submenu items. With the submenu items displayed, press h to
access the flange pattern pane.
While in the pattern

pane, use f/g
to highlight required
flange pattern, confirming
5. It is possible to select predefined bolt patterns.

This option defines the number of bolts and their
respective positions.
›› i) Press q while in the “Edit flange” screen.
145
›› ii) When the context menu appears, press 4.
The option of selecting

predefined bolt positions
is currently possible with
circular bolt patterns only.
›› iii) Confirm bolt pattern selection by pressing e.
7.3.5 Enter dimensions

Press ß or d to return to the dimensions screen.
1. Enter the coupling center-to-sensor distance.
2. Enter the coupling diameter. The default is 100 mm (or 10” depending on unit
and language settings).
146
3. Enter the coupling center-to-flange distance.

4. Enter the RPM. The default is 1500. (1800 if units option is set to US units.)
The flange configuration can also be edited from the above screen by highlight-
ing the flanged machine then pressing e.
H Note
147
To edit the flange configura-

tion, use g to highlight
‘Edit flange’ then confirm
Measurements can now be taken.

7.4 Measure
1. Press m and then establish wireless communication between the sensor and
OPTALIGN smart computer ( refer to ‘Wireless measurement’ in section 4.4).
For vertically oriented machine trains, Static measurement mode is selected

automatically.
H
Note
2. Center laser beam as described in ‘Laser beam adjustment’ in section 5.9.

3. Rotate the shafts to the first measurement position. The reference mark and the
measurement position 0 must be aligned with each other. Use the navigation
keys to place the screen hour hand (red cursor line) to correspond with the
position of the laser and sensor on the shafts.
148
4. Press e to take the first measurement point.
H
After taking measurement point, the clock hour hand moves automatically to the
next clock position. (If the first measured position is 12:00 o’clock, then the hour
hand moves to the 1.30 o’clock position). Note
5. Rotate the shafts to the second measurement position (this could be either
1:30, 3.00, 4.30, 6.00, 7.30, 9.00 or 10.30 o’clock position). If particular
measurement positions are to be bypassed (say due to shaft rotation restrictions),
use the navigations keys and move the screen hour hand (red cursor line) to
correspond to the new position of the laser and sensor on the shafts. Press e
to take measurement point.
A minimum of three measurement positions are required to obtain results, but

it is recommended that a maximum number of measurement points be taken to
improve the quality of results.
H Note
7.5 Results
When measurement is complete, press w to view results.
The ‘all-in-one’ results

screen shows the coupling
gap and offset values in the
0-6 and 3-9 directions for
short flex coupling and the
flange correction values.
149
Sign convention (for vertical machines)

POSITIVE GAP opens towards 0:00 or 3:00
POSITIVE OFFSET if the top coupling half is offset towards 0:00 or 3:00
H Note
Cycle through the coupling results and the flange correction positions using either
w, f or g.
In this example, the sad face

smiley indicates that the
flange needs to be adjusted
in the 0-6 direction.
The shimming correction

value (0.91 mm) and
150 the corresponding bolt
(position 1) are highlighted
automatically as shown.
The shim corrections are numbered to correspond with the bolt positions. The bolt
position corresponding to the currently highlighted calculated shim correction value
appears numbered and highlighted with a yellow dot.
Use i/h to cycle through the shim values.
The shimming mode to be applied is set using the “Flange corrections” screen context
menu item ‘Change correction format’. The currently applied shimming mode appears
on the header of the “Flange corrections screen.
current shimming mode (+)
The following options are available:

Bolt correction (+) – means all shimming corrections are positive (add shims)
Bolt correction (-) – means all shimming corrections are negative (remove shims)
Bolt correction (+) – means all shimming corrections are minimized (optimized).
Therefore half of the corrections will be negative and half of them positive. This
option results in zero axial movement of the shaft.
To cycle through the three available shimming modes, press q while in the “Flange
corrections” screen, then highlight the context menu item ‘Change correction format’
and confirm selection by pressing e. The shimming mode changes from (+) to (-)
then to (+).
“Flange corrections” screen may also be accessed via “Results” or “Feet results” 151
screens context menu item ‘Flange corrections’. Press q while in either screen then
use g/f to highlight the context menu item ‘Flange corrections’.
Confirm selection by pressing e. The shim corrections screen appears.
7.6 Machine alignment
Alignment is carried out by correcting angularity and offset.
7.6.1 Correcting angularity

1. Loosen the flange bolts and lift the upper machine.
The machine bolts must be undamaged and removable.
2. Angularity corrections are made by shimming. The shim correction screen shows
a
CAUTION
the shimming values at the respective bolt locations. Insert (or remove) shims
with the correct thickness under the selected bolt.
Use good quality shims such as PERMABLOC, LAMIBLOC or MYLAR.
3. Retighten the bolts and then remeasure to verify shimming results and determine
HNote
the exact alignment condition.
7.6.2 Correcting offset

The correction of offset misalignment is carried out using the Live Move function.
1. Access Live Move by pressing q while in “Results” screen. Use g/f to
highlight the context menu item ‘Move’.
152

3. On confirmation the screen used to position the sensor and laser for the required
move appears. Select the most convenient position.
If for any given reason

one would like to initially
perform Live Move in a
different view as presently
displayed, the “Move”
screen context menu item
‘Change view’ is used to
select the required view.
4. Rotate shaft to any of the eight positions highlighted in green. These are 1:30,
3:00, 4:30, 6:00, 7:30, 9:00, 10:30 and 12:00.
It is recommended whenever practical to choose a position where the sensor is

oriented along the same axis as one wishes to move the machine, so that the
move will be tracked along the sensor’s Y-axis.
H Note
5. Use i to position the sensor on the screen to correspond to the position of the
sensor and laser on the shafts.
6. Press e to start Live Move.
If the laser beam is centered, Live Move starts automatically. If beam is not
centered, a hint to center the laser beam appears on the display.
H Note
7. Loosen the flange bolts. Move the machine laterally in the direction of the bold 153
yellow arrow as indicated in the Live Move display.
8. Corrections should be brought as close as possible to zero. The smiley changes

from a sad face to OK to a happy face. At the same time the OPTALIGN smart
computer LEDs change from red to amber to green and to blue.
Use appropriate tools (e.g. levers) to position the machine.

Take care not to let the shims slip out of place during lateral positioning.
When machine is correctly positioned, tighten the bolts back down. Remeasure
H
Note
to check if the new alignment condition is within tolerance.
The orientation of the Live Move may be changed via the context menu of the
“Move” screen.
154
Configuration
Chapter 8: Configuration and data

management
8.1 Shortcut numbers
OPTALIGN smart computer menu items are accessed using the navigation keys. The
navigation direction is either upwards/downwards or sideways. Alternatively, use may
be made of the data entry keys which provide navigation shortcuts.
All context menu items are labelled with digits for quick access. The required
menu item is accessed directly by pressing the corresponding numerical data
entry key.
H
Note
8.2 Configuration
The menu item ‘Configuration’ is used to configure the OPTALIGN smart computer
settings, the regional settings, default settings, shaft application settings, printing
settings and licencing of available applications.
With the computer switched on, access ‘Configuration’ by pressing q twice. The
expanded menu as shown below appears.
155
With expanded menu displayed, use f/g to highlight the context menu item
‘Configuration’, then press e to confirm selection. The “Configuration” screen
displaying items that can be configured appears.
Each item in the configura-

tion screen can be opened
by pressing the correspond-
ing data entry key (e.g.
pressing 6 opens the
“Shaft settings” screen).
8.2.1 Device settings

The “Device settings” screen is opened by highlighting the ‘Device settings’ icon using
the navigation keys then confirming selection by pressing e. Alternatively, press
1 to directly access the “Device settings” screen. The available settings include
brightness, keyboard beep, power scheme, battery level, resume policy and Bluetooth.
Use f/g to select item to be set.
156
The display brightness is adjusted using h/i.

Configuration
To turn the keyboard beep on/off, press e. The on/off box appears. Use f/g
to select either ‘on’ (to enable the beep) or ‘off’ (to disenable the beep). Press e to
confirm selection.
157
The power scheme option is used to select setting that manages the power usage
within the OPTALIGN smart computer. The four available options are: ‘Standard’
(the display dims after 10 minutes and shuts down after 1 hour), ‘Full power’ (no
dimming and no shutdown), ‘Use standby’ (no dimming and shutdown is after 1
hour) and ‘Long life’ (the display dims after 3 minutes and shutdown takes place
after 10 minutes). The required setting is selected using f/g and selection
confirmed by pressing e.
The capacity of the battery appears next to the battery level bar.
158 ‘Resume policy’ allows the user to specify the measurement file that opens when
the system computer is turned on. The system may be set to open the last used
measurement file (‘Always resume last file’) or open a new measurement file (‘Resume
manually’). The option may also be used to open measurement files based on date
last used. With ‘Resume policy’ highlighted, press e to display the available resume
options. Use f/g to highlight preferred resume option. Confirm selection by
pressing e.
Configuration
The item ‘Bluetooth’ is used to enable or disenable the Bluetooth capabilities of the
e with the
OPTALIGN smart computer. To turn Bluetooth capabilities on/off, press
item highlighted. The on/off box appears. Use f/g to select either ‘on’ (to
enable Bluetooth capabilities) or ‘off’ (to disenable Bluetooth capabilities), then press
e to confirm selection.
8.2.2 Regional settings

This option is used to set the units of measurement, the preferred country language,
current date and time. The screen is opened by highlighting the ‘Regional settings’
icon using the navigation keys then confirm selection by pressing e. Alternatively,
press 2 while in “Configuration” screen to directly access the available settings.
159
Highlighting ‘Units’ using f/g then confirming selection by pressing e

reveals the available units of measurement. These are the US units, the English units
and the SI (metric) units.
Select the required system of units using f/g. Press e to confirm selection.
Highlighting ‘Language’ using f/g then confirming selection by pressing

e displays a list of the available country languages. Select the preferred country
language using f/g. Press e to confirm selection.
Highlighting ‘Time zone’ using f/g then confirming selection by pressing e

displays the different time zones. The required zone is selected using f/g and
confirmed by pressing e.
When a time zone is initially

highlighted, a hint appears
displaying major world cities
within the selected time
zone. Note that changing
the time zone automatically
alters the time set.
Current date and time are set by highlighting the respective option using f/g
then confirming selection by pressing e.
160
Use h/i to highlight either date, month or year.

Configuration
Set the date using the data entry keys then confirm entry using either ß or e.
Alternatively, both date and time can be set using f/g.
161
The format in which the date or time is displayed is set via the item ‘Date/time format’.
Use f/g to highlight the menu item ‘Date/time format’.
Pressing e with ‘Date/time format’ highlighted reveals a menu box with the items
‘Date format’ and ‘Time format’. Usef/g to select either item, confirming
The time format is used to set either the 12h or 24h notation. The selected notation
is confirmed by pressing e.
The date format is used to set dd-mm-yyyy or mm/dd/yyyy format.
162
Configuration
8.2.3 Default settings

The “Default settings” screen is opened by highlighting the ‘Default settings’ icon use
the navigation keys then pressing e to confirm selection. Alternatively, pressing 3
while in the configuration screen to directly access the available settings. The screen is
used to set specific default parameters. The default changes are effective upon restart
or if a new file is created.
‘Default RPM’ – used to set the required default rpm. Use f/g and
highlight ‘Default RPM’ then use the data entry keys to enter the required
default rpm. Confirm entry by pressing either e or ß. Every new alignment
file created will then automatically be preconfigured with this RPM value already
entered.
‘Reference diameter’ – used to set the required reference diameter. Use
f/g and highlight ‘Ref. diameter’ then use the data entry keys to enter
the required reference diameter. Confirm entry by pressing either e or ß. 163
Every new alignment file created will then automatically be configured with this
coupling diameter value already entered.
‘Default sensor’ – The system’s default sensor is the RS5 BT sensor. Depending
on the system configuration, the default sensor may be set to RS5 sensor or
ROTALIGN sensor or OPTALIGN sensor.
Use f/g and

highlight ‘Default sensor’,
and then press e. The
default sensor options
appear. Use f/g
and highlight required
default sensor, and the
confim selection by pressing
e.
‘Workflow assistant’ – used to determine the guidance steps required to carry

out an alignment job. The three options available are: ‘On’, ‘Sensor-coupling
distance auto calculation’ and ‘Off’.
164
Default mode – used to set the default measurement mode. Three measurement
modes are available – Sweep, Multipoint and Static modes.
Configuration
‘Results resolution’ is used to set the results resolution at either ‘Normal’ or

‘High’.
Alignment results and units used Result resolution normal Result resolution high
Coupling results ( mm / mrad ) 2 decimal places x.xx mm 3 decimal places ( 1 µm res. )

x. xxx mm
Foot results ( mm ) 2 decimal places x.xx mm 2 decimal places x.xx mm
Coupling results 1 decimal place 1 decimal place

( mils / mils per inch )
Foot results 1 decimal place rounded off to 1 decimal place xxx.x

( mils ) 1/2 mil ( 0.5 mil, 1 mil, 1.5 mils )
8.2.4 Licence manager

This option is used to licence all possible system applications. The “Licence manager”
screen is opened by highlighting the ‘Licence manager’ icon using the navigation keys
then confirming selection by pressing e.
Use the navigation keys to

highlight the ‘Feature key’
and ‘Licence code’ boxes.
Enter the received key and
code values using the data
entry keys.
165
Use the data entry keys to enter the application licence code. Press e to activate
the application.
In most cases, the system is delivered with Shaft Alignment application licenced for
the default features level.
The following features are available in the default features level:
Continuous Sweep measurement mode
Static measurement mode
Dynamic tolerance table
Customer-defined tolerances
Saving up to 500 measurement files
Extend detector area
Ability to print reports directly from the OPTALIGN smart computer
PDF report
Soft foot measurement
Ability to define static feet
Results table to verify measurement repeatability
Checking pipe strain
Multiple feet machine correction (six feet machines)
Averaging
Vertical machine alignment
Dial gauge input
Targets
Supporting OPTALIGN, ROTALIGN, RS5 and RS5 BT sensors
To find out which features are available on your particular instrument, press q while
in the “Licence manager” screen.
The menu item ‘About’

166 (described later within this
section) provides a quick
overview of important
information related to the
instrument and the installed
features.
Use either f or g to highlight ‘Feature list’. Press e to confirm selection.

Configuration
Use f/g to scroll

through the features list.
Missing features may be ordered from PRÜFTECHNIK Condition Monitoring.

Please contact your local representative for ordering details.
All missing optional features may be acquired in one go by ordering part
H
Note
number ALI 12.710 [All Additional Features].
To register any feature, press q while in the “Licence manager” screen, then use
either f or g to highlight ‘Register feature’.
167

Use the navigation keys to

highlight the ‘Feature key’
and ‘Licence code’ boxes.
Enter the received key and
code values using the data
entry keys. The feature is
now activated and ready
for use.
8.2.5 About application

The information contained under this section is accessed by pressing 3 with the
licence manager context menu open. The displayed information depicts the current
status of the device and application.
168
8.2.6 Printer configuration

This option is used to set up printers and the printing configuration in OPTALIGN
smart computer. The “Printer configuration” screen is opened by highlighting the
‘Printer configuration’ icon using the navigation keys then confirming selection by
pressing e.
Configuration
The default printer type

is ‘PDF file’. This option is
used to save measurement
reports as a PDF file directly
to an approved USB
memory stick.
Four printing options can be set using ‘Printer configuration’.
Type – Selecting ‘Type’ and then pressing e displays a list with all supported
printers.
If a different printer type

has been selected, one
may revert back to the
default printer ‘PDF file’ if
desired, by pressing 0
when the printer options
are displayed. Alternatively,
select desired type using
f/g. 169
Paper – Used to select the required paper size

Orientation – Used to set the paper orientation. Select ‘Portrait’ for a vertical
layout and ‘Landscape’ for a horizontal layout.
Colour mode – Used to set the colour mode in which the measurement report is
to be printed. This can either be in full colour or in grayscale.
8.2.7 Shaft settings

The “Shaft settings” screen is opened by highlighting the ‘Shaft settings’ icon using
the navigation keys then pressing e to confirm selection. Alternatively, press 6
while in the configuration screen to directly access the available settings. The screen is
used to set specific shaft alignment parameters. The settings are effective immediately.
Spacer format – used to specify how spacer coupling results are displayed. Seven
options are available.
Short flex format – used to specify how short flex coupling results are displayed.
Two options are available.
Angle format unit – used to specify whether angularity should be displayed in
degrees or milliradians.
All-in-one results – used to activate or deactivate the option to display both feet
and coupling results within a single screen
170 User tolerance type – used to allow user tolerances be defined in either
“symmetrical” or “non-symmetrical” form
Tolerance table – the available options are 50 Hz and 60 Hz. The mains supply
frequency determines the standard rpm values that appear in the tolerance table.
Tolerance values based on these frequencies may be read off the suggested
PRÜFTECHNIK tolerance table.
Auto Sweep – used to activate or deactivate ‘auto sweep’ [if deactivated,
Continuous Sweep measurement takes place only after pressing e]
Configuration
8.3 Data management
OPTALIGN smart computer possesses an effective file and data management facility.
The file and data management options are accessed by pressing q twice.
Use h/i to cycle the

cursor between the two
panes.
Note: By ‘cursor’, we are
referring to the orange
highlight bar.
Use h to access the box with the file and data management options. These are
‘Open file’, ‘Save file’, ‘New file’, ‘Print’ and ‘About’.
‘Open file’ – This option is used to load any stored file, and may be accessed from
the “Machine dimensions” screen above. Use the navigation keys and highlight the
context menu item ‘Open file’ then confirming selection by pressing e. The “Open
file” screen opens displaying a list consisting all stored files.
171
Use f/g and highlight file to be opened, and then press e to open the file.
‘Save file’ – This option is used to save the current file. If the file is new and does not
yet have a name, use the data entry keys to enter the new file name in the editing
box that appears.
Press either ß or e to confirm file name.

If the file name already exists, the editing box appears with the existing file name
highlighted. This may be overwritten or replaced with a new file name.
‘New file’ – This option is used to create a new measurement file.
‘Print’ – This option is used to save the measurement report as PDF directly to a
memory stick or print the report or the soft foot measurement report using any one
of the available printers.
172
Configuration
The following report options are available:

Complete report – this option prints a complete report that includes machine
graphics and measurement results in both numerical and graphical format.
Graphical report – reports printed using this option display only graphical repre-
sentation
Text report – this option generates reports only in text format
Pipe strain measurement report – this option is used to generate the pipe strain
check report
Change printer to configured printer – this item is used to toggle between the
default setting ‘PDF file’ and the configured printer. To configure a new printer,
press q while on this screen then use f/g to highlight the context
menu item ‘Printer configuration’. Confirm selection by pressing e, then
proceed as described in section 8.2.6 ‘Printer configuration’ previously.
173
174
Appendix
Chapter 9: Appendix
9.1 Updating system to a newer firmware version
H
System firmware updates are carried out using the especially approved
PRÜFTECHNIK USB memory stick ALI 17.451.
Check the PRÜFTECHNIK website [www.pruftechnik.com] to obtain the Note
latest version. If in doubt, please contact your local representative or
PRÜFTECHNIK Condition Monitoring.
If the update is acquired via the website, it must be transferred to the
approved memory stick before commencing the update.
Old PRÜFTECHNIK memory sticks must be disposed of in accordance to the direc-

tive on Waste Electrical and Electronic Equipment (WEEE).
9.1.1 Downloading the firmware from the PRÜFTECHNIK website

The file available for download is an .exe file. Download the file to the desired
directory on a PC.
Note: The update .exe

file is referred to as
‘OPTALIGN smart Shaft
Firmware’.
175
Double-click the file to extract it to the approved memory stick. The following screen
with instructions on how to extract the firmware files into the memory stick appears.
Click ‘Browse’ to select the

location of the approved
PRÜFTECHNIK memory
stick, then click ‘Install‘ to
start file extraction.
9.1.2 Carrying out the firmware update

The firmware update is carried out using the memory stick and the ‘short’ USB cable
ALI 12.503. The actual update does not require a PC.
Before starting the update verify that the USB memory stick has the following files
on it.
The displayed files

and folder are viewed
by expanding the
folder ‘optalign‘. The
downloaded version is
indicated by the prefix
v3_xx_yyyy, where 3_xx
represents the firmware
version and yyyy the build
1. Press e to switch OPTALIGN smart computer on. Wait for the dimensions
number.
screen to appear, then press q to view the battery capacity.
176
Battery charge capacity
Before proceeding with the update ensure that the indicated nominal capacity
of the battery is greater than 50%. If this is not the case, recharge the battery to
full capacity first (if using the rechargeable battery package), or replace all six AA
H Note
batteries at the same time.
2. Attach the ‘short’ USB cable ALI 12.503 to the OPTALIGN smart computer
socket.
3. Insert the approved PRÜFTECHNIK USB memory stick ALI 17.451 into the ‘short’
USB cable.
Appendix
4. The system beeps and the LEDs flash. A hint indicating the availability of a new
firmware and the need to reboot the OPTALIGN smart computer appears.
177
5. When the hint above appears, press and hold down e until the device reboots.
The display goes dark.
6. The update process will start automatically after a little while (as long as 10
seconds). The system beeps and an LED flashes as the process begins.
Do NOT turn off the device or remove the memory stick during the entire update
process, which takes up to 10 minutes. H
Note
7. When the process is completed, the following hint appears on the display.
178
8. Detach the USB cable from the OPTALIGN smart computer then press and hold
down e until the device resets.
OPTALIGN smart computer is now ready for use with the uploaded firmware version.
Appendix
9.1.3 Checking the uploaded firmware version

1. After the opening dimensions screen appears, press q then use the navigation
and highlight ‘More’ -> ‘About’
2. Press e to confirm selection. The application information screen appears.
The application details

include the uploaded
firmware version, the
application build, currently
loaded features among
others.
179
9.2 Sensor firmware update

Firmware updates for the RS5 BT sensor is carried out directly via OPTALIGN smart
computer. If an RS5 BT sensor working with an older firmware version is connected
to the OPTALIGN smart computer, a hint indicating that the sensor firmware requires
updating appears on the display.
Use f/g to
select ‘Yes’/’No’ respec-
tively. Confirm selection by
pressing e.
To update the sensor, use f/g to select ‘Yes’ then press e. The sensor
firmware update wizard appears.
The wizard guides the

user through the sensor
firmware update in self-
explanatory steps.
180
Before commencing with the sensor firmware update, ensure that the sensor is
fully charged. If sure that sensor is fully charged, use i/h and highlight ‘Next’
then press e to proceed with update using the sensor firmware update wizard
a
CAUTION
(Refer to section 9.2.2 “Proceeding with the sensor firmware update”.) The up-
date process takes about 5 minutes.
Appendix
9.2.1 Checking sensor charge capacity

The charge capacity of the sensor is checked from the “Measurement” screen. Use
i/h and highlight ‘Exit’. Press e to confirm selection and exit the update wizard.
In the “Measurement” screen, the sensor charge capacity is displayed by the battery
icon and the percentage.
Charge the sensor if not fully charged.
9.2.2 Proceeding with the sensor firmware update

To proceed with the update after exiting the wizard, press q while in the
“Measurement screen then use g/f and highlight the menu item ‘XY View’.
181
Press e to confirm selection. The “XY View” screen opens. Press q while in the
“XY View” screen then use g/f and highlight the menu item ‘Sensor firmware
upgrade’.
Confirm selection by pressing e. The sensor firmware update wizard opens.
182 It is strongly recommended that the sensor firmware update be carried out.
Use i/h and highlight ‘Next’ then press e to proceed with the sensor firmware
H
Note
update.
Appendix
After successful completion of the sensor update, the following screen appears.
Reboot the OPTALIGN smart computer to resume with measurement.
9.2.3 Checking sensor firmware version

The firmware version of the RS5 BT sensor may be checked at any time. To do this,
proceed as follows.
1. Switch the sensor on.
2. Press m to access the measurement screen. While in the measurement screen,
press q to display the context menu.
3. With the context menu displayed, use f/g and highlight “XY View”.
183
4. Press e to confirm selection. The XY View screen appears.

5. With the XY View screen displayed, press q to display the context menu. Use
f/g to highlight the menu item “Sensor check”.
6) Press e to confirm selection. The current sensor information including the sensor firmware version is
displayed.
184
Appendix
9.3 Suggested shaft alignment tolerances
[RPM] metric [mm] inch [mils]
Soft foot any 0.06 mm 2.0 mils
Short “flexible” couplings Acceptable Excellent Acceptable Excellent

OFFSET
600 9.0 5.0
750 0.19 0.09
900 6.0 3.0
1200 4.0 2.5
1500 0.09 0.06
1800 3.0 2.0
3000 0.06 0.03
3600 1.5 1.0
6000 0.03 0.02
7200 1.0 0.5
ANGULARITY 600 15.0 10.0

coupling gap difference
750 0.13 0.09
per 100 mm or 10”
diameter
900 10.0 7.0 185
1200 8.0 5.0
1500 0.07 0.05
1800 5.0 3.0
3000 0.04 0.03
3600 3.0 2.0
6000 0.03 0.02
7200 2.0 1.0
[continued]
Spacer shafts and [RPM] metric [mm] inch [mils]

membrane (disk)
Acceptable Excellent Acceptable Excellent
couplings
OFFSET 600 3.0 1.8

(per 100 mm spacer
750 0.25 0.15
length or per inch of
900 2.0 1.2
spacer length)
1200 1.5 0.9
1500 0.12 0.07
1800 1.0 0.6
3000 0.07 0.04
3600 0.5 0.3
6000 0.03 0.02
7200 0.3 0.2
186
Appendix
9.4 OPTALIGN smart RS5 BT technical data
Computer
CPU Marvell XScale PXA270 running at 520 MHz
Memory 64 MB RAM, 64 MB Flash
Display Type: TFT, transmissive (sunlight-readable), 65 535 colours, backlit LED
Resolution: 320 x 240 Pixel
Dimensions: 3.5 inch (89 mm) diagonal
Keyboard elements: Navigation cursor cross with up, clear and menu
keys; Alphanumeric keyboard with dimensions, measure and results hard
keys
LED indicators 4 LEDs for laser status and alignment condition
2 LEDs for wireless communication and battery status
Power supply Disposable batteries: 6 x 1.5 V IEC LR6 (“AA“)
Lithium-Ion rechargeable battery: 7.4 V / 2.5 Ah / 18.5 Wh (optional)
Operating time: 18 hours typical use (based upon an operating cycle of
25% measurement, 25% computation and 50% ‘sleep’ mode)
External interface USB host
USB slave
RS232 (serial) for sensor
Integrated wireless communication, class 1, transmitting power 100 mW
AC adapter/charger socket
Environmental protection IP 65 (dustproof and water jets resistant), shockproof
Relative humidity: 10% to 90%
Temperature range Operation: -10°C to 50°C [14 °F to 122°F]
Storage: -20°C to 60°C [-4°F to 140°F]
Charging: 0°C to 40°C [32°F to 104°F]
Dimensions Approx. 214 x 116 x 64 mm [8 7/16” x 4 7/16” x 2 1/2”]
Weight 865 g [1.9 lb]
CE conformity Refer to the CE compliance certificate in www.pruftechnik.com
187
RS5 BT sensor
Type 5-axis sensor: 2 planes (4 displacement axes and angle)
Measurement area: unlimited, dynamically extendible (U.S. Patent 6,040,903)
Resolution: 1 µm (0.04 mil) and angular 10 μRad
Accuracy (avg): > 98%
Measurement rate: approx. 20 Hz
Inclinometer Resolution: 0.1°
Error: 0.3% full scale
LED indicators 1 LED for laser adjustment and battery status
1 LED for Bluetooth communication
Power supply Lithium-Ion rechargeable battery: 3.7 V / 5 Wh
Operating time: 10 hours (continuous use)
Charging time: Using charger – 2.5 h for up to 90%; 3.5 h for up to 100%
Using USB port – 3 h for up to 90%; 4 h for up to 100%
External interface Integrated Bluetooth 4.1 Smart Ready wireless communication
USB 2.0 Full Speed
Transmission distance Up to 30 m [98 ft] direct line of sight
Ambient light protection Yes
Temperature range Operation: -10°C to 50°C [14 °F to 122°F]
Charging: 0°C to 40°C [32°F to 104°F]
Weight Approx. 235 g [8 1/3 oz.]

RS5 laser
Type Semiconductor laser diode
Beam divergence 0.3 mrad
Beam power < 1 mW
Wavelength 630 – 680 nm (red, visible)
Safety class Class 2 according to IEC 60825-1:2007
The laser complies with 21 CFR 1040.10 and 1040.11 except for
deviations pursuant to Laser Notice No. 50, dated June 24, 2007.
188 Safety precautions Do not look into laser beam
Power supply Batteries 2 x 1.5 V IEC LR6 (“AA“)
Operating time: 180 hours
Temperature range Operation: -10°C to 50°C [14°F to 122°F]
Weight Approx. 225 g [7 15/16 oz.]
Carrying case
Standard ABS, drop tested 2 m [6 1/2 ft]
Weight Including all standard parts: approx. 8.3 kg [18.3 lb.]
Index
Index
Symbol
3-machine train B
ALI 12.723 123
Battery
3-machine trains 123
disposal 21
A Battery housing
ALI 12.600 18
Adjustment thumbwheels Battery icon
yellow 70 sensor 73
ALI 2.118 Beam adjustment
small chain-type bracket 7 crosshair 73
ALI 12.200 Bluetooth
computer 5 on/off 159
ALI 12.201 Bracket
computer stand 5 anchor peg 41
ALI 12.502-2 mounting 41
PC cable 7
ALI 12.503 C
USB cable 7
ALI 12.600 Cardan drive machines 123
battery housing 19 Cardan drives
ALI 12.651-I set-up 138
AC power supply / charger 19 Cardan shaft bracket lite
ALI 2.874 SET iS 133
AC power supply/charger 18
Case
ALI 12.701
OPTALIGN smart RS5
shaft firmware certificate 8
ALI 12.713 ALI 12.805 5
optional features CE compliance 11
Changing orientation 154 189
targets, thermal growth, dial gauge 50 Charger [universal]
Alignment condition 81
Alignment condition LED OPTALIGN smart
computer ALI 12.651-I 19
OPTALIGN smart RS 34 Charger, universal
Alignment condition LEDs 131 OPTALIGN smart
All additional features ALI 12.651-I 6
optional
RS5 BT sensor
ALI 12.710 167
ALI 3.953 6
All-in-one results 126, 149, 170
Compact chain-type bracket 27
Angle format unit
Compact magnetic bracket
degrees 170
ALI 2.112 27
Angle format units
Computer keyboard 17
milliradians 170 Correcting offset
Auto Sweep 74, 170 vertical alignment 152
Averaging 119 Coupling
type 57
Coupling position I
jumping 128
Coupling target 57 Infinirange 116, 118
In-house standards 63, 77
D Inspection
label 14
Data entry key
system 13
numerical 155 IP65
Data storage 13 computer 13
Default measurement mode 164 IP classification 11
Default mode 166
Default sensor 163
J
Default settings 163
Device settings 156 Job preparation 39, 86
Dial gauge
configuration 65 L
Dial indicator readings
Labelling 14
conversion 65
Laser adjustment 131
Display brightness 156
Laser batteries 20
Disposal
Laser beam adjustment 69, 103
WEEE 13
Laser centered 73
Distance marking 45
Laser classification
Distance sleeve 135
Distance sleeves IEC 60825-1:2007 12
Laser end 73
black 135 Laser holder 134
Dust cap Laser off 73
opening aperture Laser OK 73
RS5 sensor/laser 25 Laser safety
Class 2 20
E Laser-sensor separation
maximum 40
Editing box 44 Lens cleaning cloth
190 Extending measurement range 73, 92, 116 ALI 2.911 7
Extending range Licence code 165, 168
Laser end 116 Licence manager 165
Extra-thin bracket Lithium-ion rechargeable battery
ALI 2.109 SET 27
ALI 12.601
optional 18
F
Live Move 87
Feature key 168 direction 87
File resume policy 158 points to observe 92
Finishing alignment 91
Flange configuration 143
Flanged machines 123
M
Flip function 67 Machine name
Flip machines 47
editing 50
Machine train
set-up 123
Machine trains 123
Index
Magnetic brackets P
transportation 27
Package, standard
cover plate 27
Magnetic bracket set OPTALIGN smart RS5
ALI 2.761 SETIS 27 ALI 12.015-RS5R 5
Magnetic sliding bracket PDF file 169
ALI 2.230 27 Pipe strain 108
Marking measurement positions measurement report 111
vertical shafts 142 Pipe strain wizard 108
Measurement details 80, 118 Pocket guide
Measurement mode OPTALIGN smart RS5 BT
Continuous Sweep 74 DOC 12.106.en 8
Multipoint 74, 113 Power scheme option 157
Predefined bolt patterns 145
Static 114 Printer configuration 96, 168
Static measurement 74 Printing
Measurement modes 74, 113 measurement reports 95
Measurement rotational arc 75 Printing options 96, 172
Micro USB cable Product catalogue
ALI 3.952 6, 23 OPTALIGN smart RS5
Mounting DOC 12.905.en 8
RS5 sensor, RS5 laser 42 PRÜFTECHNIK website 11
Move corrections
machine train 130 Q
Multiple feet 78
Multiple feet calculator 78 Quarter-turn screw 18
Multipoint measurement mode Quick alignment check 99
ALI 12.715
R
optional feature 114
Multipoint measure mode Rechargeable battery
ALI 12.715 OPTALIGN smart
optional feature 139 ALI 12.601 5 191
Reference diameter 163
N Reference mark 148
Reference surface 134
Negative dimensions Regional settings 159
entering 46 Results
All-in-one 76, 100
O sign convention 76
Results resolution 165
Operating handbook Results screen
OPTALIGN smart RS5 BT ‘all-in-one’ 35
DOC 12.206.en 8 Results table 79
OPTIONAL icon 2 list 79
measurement details 80
Resume function 119
RPM
default 163
RS5 laser
ALI 3.910 6
S System language 160

System units 159
Safety and general information
OPTALIGN smart RS5 T
DOC 12.601 8
Tape measure
Safety data sheets
ALI 3.589 7
magnetic brackets 27
Technical data
Safety symbols 11
Saving OPTALIGN smart RS5 187
as a PDF file 95 Temperature
effects, fluctuations 12
measurement file 94
Saving file 171 operating range 12
Screen header 151 Thermal growth 50
Sensor Thermal growth calculator 53, 54
Tolerance 77
ALI 3.901 138
Tolerances 60
charging 23
non-symmetrical 60, 170
inspection certificate
suggested 185
ALI 9.516.DG 8
symmetrical 60, 170
LEDs 23
user defined 60, 82
RS5 with Bluetooth Tolerance table 62, 63, 82, 170
ALI 3.901 6 Train elements 124
Setting date and time 161 Train orientation 47
Shaft settings 100, 170
Shimming 86 U
vertical 86
Universal adapter/charger
Shimming correction 150
Shims mounting and dismounting 19
good quality 86 Universal charger
ALI 3.951 26
PERMABLOC or LAMIBLOC 152
Shortcut numbers 155 mounting,dismounting 26
192 Short flex format 170 USB cable ‘short’
Smiley 36 ALI 12.503 176
Soft foot 101 USB memory stick
angular 101 ALI 17.451 7, 95
correction 107 approved
checking and correcting 102 ALI 17.451 175, 176
parallel 101
correction 107
V
Spacer Vertical machine
spool piece 46
alignment 142
Spacer format 170
Spacer shaft
ALI 12.718
optional feature 138
Standard deviation 80
Standard machine
generic 49
Index
W
WEEE
electronic waste 175
Wireless communication
establishing 71
Workflow assistant 164
X
XY view 73, 88, 103
XY View 121
absolute values 121
relative coordinates 122
relative mode 122
193
194

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A user’s handbook

OPTALIGN® smart RS5 is a registered trademark of PRÜFTECHNIK Dieter Busch AG.

PRÜFTECHNIK Condition Monitoring

Chapter 1: OPTALIGN smart RS5 BT packages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Chapter 2: Safety notes and operating information. . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Chapter 3: OPTALIGN smart RS5 BT – Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Chapter 4: Getting started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Chapter 5: Horizontal machine alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5.17 Checking and correcting soft foot conditions............................................................. 102

Chapter 6: Alignment features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Chapter 7: Special alignment applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Chapter 8: Configuration and data management. . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Chapter 9: Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Chapter 1: OPTALIGN smart RS5 BT

ALI 12.015-RS5R is the standard OPTALIGN smart RS5 BT package.

1.1 OPTALIGN smart RS5 BT package with rechargeable

ALI 12.805 OPTALIGN smart RS5 case

ALI 12.200 OPTALIGN smart computer including

ALI 12.201 Computer stand

ALI 12.805 ALI 12.200 ALI 12.201

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 3.910 ALI 3.953

ALI 3.952 ALI 12.651-I

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

ALI 2.118 Small chain-type bracket [Note that the

ALI 2.911 Lens cleaning cloth

ALI 3.589 Tape measure mm/inch

ALI 2.911 ALI 2.118 ALI 3.589

ALI 12.701 OPTALIGN smart shaft

DOC 12.106.en OPTALIGN smart RS5 BT pocket guide

DOC 12.206.en OPTALIGN smart RS5 BT operating

DOC 12.601 OPTALIGN smart RS5 BT safety and

DOC 12.905.en OPTALIGN smart RS5 product catalogue

ALI 9.516.DG RS5 BT sensor inspection certificate (not

DOC 12.905.en DOC 12.106.en

1.2 OPTALIGN smart RS5 BT package ALI 12.015-RS5

ALI 12.600 OPTALIGN smart RS battery housing

Page intentionally left blank

Chapter 2: Safety notes and operating

2.1 Safety notes

OPTALIGN smart RS5 BT is to be used in industrial environments only for shaft

2.1.1 Safety symbols

This symbol denotes general information and tips regarding operation of

This symbol denotes information which must be followed in order to avoid

This symbol denotes information which must be followed in order to avoid

Numbers in red circles indicate the corresponding operating step described in

2.1.2 CE compliance and electromagnetic compatibility

2.1.4 Laser safety

2.2 Operating information

2.2.1 Temperature range

2.2.2 Temperature effects and fluctuations

2.2.3 Incident light

2.2.4 Dust and water seals

2.2.5 Interface connection

2.2.6 Notes regarding data storage

PRÜFTECHNIK assumes no responsibility for data lost or altered as a result of

PRÜFTECHNIK assumes no responsibility, directly or indirectly, for financial losses

d — The ‘Dimensions’ key is used to initiate entry of machine dimensions.

ß — The ‘Up’ key is used to confirm entered values, and as a back/return

c — The ‘Clr’ (Clear) key is used to delete information entered inadvertently.

h i f g — The navigation keys are used to navigate through the

e — The ‘On/Off/Enter’ key is used to perform four functions – switching