Chapter 5 Using UltraSpec Alignment - General Overview This chapter covers the following topics: • UltraMgr/UltraSpec Analyzer Overview • Storing, recalling, and modifying jobs • Defining a job • Machine Dimensions • Soft Foot • View Data • Checking data • Viewing machine moves • Printing an alignment job 1 5-1
General Overview This section contains overviews of UltraMgr and the UltraSpec analyzer, the three alignment methods, menu maps of the UltraSpec analyzer, and an explanation of the Main Menu. UltraMgr/UltraSpec Analyzer Overview The figure below shows how jobs can be moved in and out of various areas of UltraMgr’s database and the analyzer. Definitions of the job types follow.
Note This manual and the UltraSpec Analyzer manual use the terms Station and Machine. In RBMware compatible UltraMgr v4.00 and later, a station may be preferred to as Area, and Machine may be referred to as Equipment unless redefined by the user. Note Data from the 8215 and 8225 laser heads are compatiable with UltraMgr v4.40 and later. Definitions of the job types shown in the figure are: • Assigned jobs – jobs that have been assigned to a machine.
Continuing with the UltraMgr program, you can then assign the job to a machine and station thereby fully integrating the job information into the UltraMgr database. If for some reason you do not want to assign the job to a machine and station, you can leave it in the Unassigned Area. In either case, you can then use UltraMgr to Load the job back into the analyzer and from that point, you can recall it into the Current Job area where you have full editing capabilities.
Referring back to the UltraMgr/UltraSpec analyzer overview figure, the UltraMgr PC is shown as the master and the UltraSpec analyzer is shown as a slave. This means that actual transactions between the UltraMgr PC and the analyzer are controlled by UltraMgr. Although you must make the following analyzer selections to prepare for a job transfer, (1) Utility (2) Communications (3) Host PC Load/Dump, the analyzer plays a passive role from that point on.
Modifications to change the Job Type to these fields Unassigned Alignment Data X Alignment Method X Coupling X Mach Desc X Mach ID X Machine Dimension: A & E (between feet) X Machine Dimension: B, C, D, & F Machine View (also called machine configuration) 5-6 Modified X X Notes X Rotation X RPM X Station X Thermal Growth X User Initials X Foot Pre-Check X Laser Configuration X Using UltraSpec Alignment - General Overview
Modified Jobs – This job type is assigned to a particular machine within UltraMgr. If a change(s) is made to a job that causes it to become Modified, it will still retain its Station and Machine assignments in UltraMgr. Note When loading a job from UltraMgr, you will receive a screen prompt that allows you to assign a new Job No./Name to the modified job. To ensure that your jobs are easy to identify, CSI recommends that you assign a new Job No./Name.
Note If, for some reason, you do not want to assign a job to the database, you always have the option of leaving it in the Unassigned Area. UltraMgr allows you to Load and Dump these jobs to the analyzer the same way assigned jobs are handled.
1 Job Definition Pro Align Plus 2 3 4 Alignment Data Foot Pre-Check Additional Selections; See Next Page 5 View Data Machine Moves Offset & Angle Graphics Acquire Data Data Detail Soft Foot Results Sine Fit Edit/View 4-Point Detail Vertical Log Horizontal Log Clear Job Define Job No Yes Data Stored Machine View Laser Configuration Machine Dimensions Thermal Growth Clear Readings and Notes Clear Complete Job Live Mode Vertical Move Live Mode Horizontal Move Reading Set Stored CSI
(continued from previous page) 1 Utility 2 3 Options 4 1 2 3 4 5 6 7 Print Screen Alt/Print Screen Alignment * Report Print Screen * When the Laser History Data screen is active, you can also print a Laser History Report Help Notes *** ** Press Alt/Notes to enter User Defined notepad area from any place in the application User Defined ** (to add new notes) Alignment Notepad (Pre-defined notes) General Observation Feet/Base Movement Related Coupling/Shaft User Defined All Notes Calculat
Main Menu Display The Main Menu items are shown and described in the following section. 6 10 1 11 2 3 4 5 7 12 8 9 Main Menu Display 1.···· Use this section to complete all items necessary to document the job properly. 2. ··· Allows you to locate feet that are causing machine problems (including relative severity). 3. ··· Section where alignment data is acquired. 4. ··· Displays graphical representation of the present alignment condition in offset and angle. 5.
9. ··· Shows the number of machine moves that have been stored in the Current alignment job (up to 20). 10. · The job number as defined in the Job Definition section. 11. · The Machine being aligned. 12. · Data collection method currently being used.
Job Definition Define Job To bring up the Define Job screen, select the Job Definition section on the Main menu. Define Job Screen Use the Up Arrow or Down Arrow to highlight the following portions of the Define Job menu. Clear Job: You can erase part or all of the Current job shown on the Define Job menu. Use any numbered key to toggle to “Yes”; press Enter and a screen showing three options will be displayed.
Press the Up Arrow or Down Arrow to highlight one of the following three selections. Press Enter to accept. (1)·· Abort, Do Not Clear – returns you to the Define Job menu with no changes to the job. (2)·· Readings & Notes Only – causes all job alignment reading sets (up to 20) and notes (up to 40) to be erased. The information in the Job Definition section will remain unchanged. You will be returned to the Define Job menu after the Readings have been cleared.
Note If the job is defined within UltraMgr, the Mach ID, Mach Desc, Station and Coupling cannot be modified within the analyzer. Mach ID: - Up to 10 characters can be used to define a Machine ID code for the machine being aligned. Mach Desc: - By pressing any key on the keypad (except Page Up or Alt), the highlighted block can be expanded. Up to 28 characters can be used to describe the machine being aligned.
Machine View Use the following screen to define how the machines will be viewed during the alignment job. In this view, the two machines are connected by one coupling. Machine View Screen The machines should be named according to how they are installed relative to the location where the user will view the machines. Choose the appropriate name with the Up/Down arrow keys and Left/Right arrow keys. Press Enter to accept the left machine. Proceed to the right machine and repeat the process.
Laser Configuration It does not matter which sensor head is put on which machine, however, the analyzer must know each head’s location. Use any keypad key to toggle from one configuration to the other. The arrows must be set to match the directions that each laser will transmit, i.e., the arrows must represent the actual laser directions by pointing away from the small circle and toward the red target. Press Enter to accept the configuration.
Machine Dimensions (A through F) Note This section assumes that the fixtures are set up to the point that the sensor heads are mounted. After accepting the configuration, the following screen will appear. Machine Dimensions (A) Screen Measure all of the dimensions to the nearest 1/8 inch (3 mm) with the exception of dimension C. Dimension C should be measured to the nearest 1/16 inch (1.5 mm).
Dimension Measurement Description Measure to Nearest A Center of outboard foot to center of inboard foot of the machine on the left. 1/8 inch (3 mm) B Center of inboard foot on the left machine to the sensor head face on the left machine. To enter a measurement for a foot that falls inside the laser face, place a negative sign (–) in front of it. 1/8 inch (3 mm) C Measure from the inside face of one sensor head to the inside face of the other sensor head. 1/16 inch (1.
Thermal Growth, Vertical Thermal Growth (Vertical) Screen This screen shows a side view of the coupled machinery. The amount of vertical thermal growth that both machines will experience during operation can be expressed in either mils or millimeters (mm). Thermal growth values should correspond to the amount each shaft will move in the vertical direction directly above each foot. If thermal growth is negligible, enter zeroes. The range of values that can be entered are -250 to 250 mils and -6.35 to 6.
Thermal Growth, Horizontal Thermal Growth (Horizontal) Screen This screen shows a top view of the coupled machinery. Horizontal thermal growth can be entered in this top view of the coupled machines. Thermal growth values (mils or mm) should correspond to the amount each shaft will move at each foot. If thermal growth is negligible, enter zeroes at all locations. One entry field at each set of feet must be zero. The range of values that can be entered are 0 to 250 mils and 0 to 6.35 mm.
Foot Pre-Check When Foot Pre-Check is selected (from the main menu) and the Job Definition screen is completed, a screen similar to the one below on the left will be displayed. The screen that is displayed depends on the type of Foot PreCheck selected (Soft Foot or Frame Distortion Index [FDI]). For more information, see the Appendix heading, “Foot Pre-Check Types” on page -1. Use the Enter key to move to the Soft Foot/FDI Locator screen (on the right).
Loosen the hold-down bolt and wait for the dial to stop. Press any number key to accept that value; the cursor will move to the next foot. Retighten the bolt and proceed to the next foot. To remove results (clear data at a single foot) and acquire new data, press Delete. To remove results at all feet (clear data at all feet), press Alt/Delete. After all feet have been checked (CSI recommends that you always check all feet), press Enter and the data will be evaluated.
If FDI is selected, the data is evaluated by default as follows: • “-----” – no measurement was made for this foot • “No Box” – excellent condition (less than 2.0) • “Clear Box” – acceptable condition (between 2.0 and 3.0) • “Dark Box” – out of tolerance (greater than 3.0) These tolerances can be changed in UltraMgr and transferred to the UltraSpec. Warning! The numbers displayed are not the required correction shims for this foot.
Alignment Data This function, available from the main alignment menu, allows you to make the raw measurements needed for the calculation of the relative positions of the shafts. This section gives a brief overview of the available data collection modes. The next chapter gives an in-depth look at each mode. Method: to provide data acquisition for varying applications, circumstances, and preferences, a number of different data collection methods are provided.
• 4 Point Auto – the four point automatic mode is a more traditional style of acquiring data for alignment. The laser heads are mounted on a shaft, and the shaft is then rotated so that data can be taken when the laser heads are at the 12 o’clock (0 or 360°), 3 o’clock (90°), 6 o’clock (180°), and 9 o’clock (270°) positions. The readings are continuously averaged whenever the laser heads are at one of these positions and automatically recorded when the shaft is rotated to the next position.
Data Quality When using Auto Sweep, Manual Sweep, or Dual Pass a sine curve is fit to the data points to determine what the projected data would be at each of the clock positions mentioned above in the 4 Point Auto method. If the fit of the curve to the data points is marginal, then the data can be automatically conditioned to improve the sine fit. The resultant fit may be viewed and can be manually conditioned if desired. This procedure is discussed in the application chapter.
View Data Dual Tolerance Plot After acquiring data, the view data function allows you to check the acceptability of the current alignment. Both the vertical and the horizontal relationships are plotted as well as the calculated values for angle and offset or left angle and right angle. The bold crosshair shows the current condition, whereas a faint crosshair is drawn to show the previous position. Use the Up/Down arrow keys to change the plot scaling if needed.
Note If more than one set of alignment data has been acquired, the last two data sets acquired will have their current conditions displayed on this screen. The last data set will have its current condition represented by the bold crosshair while the previous data set will have its current condition represented by a crosshair that isn’t bold. Individual plots displaying all alignment data sets acquired are available. Refer to “Additional Data Detail” on page 5-34 for details.
Tolerances The amount of offset and angular misalignment displayed is based upon the last full set of alignment readings. All shaft misalignment is a combination of offset and angular misalignment (see “Alignment Application Notes” on page 8-3). This screen breaks down the misalignment into each component. The amount of each type of misalignment is shown for both the horizontal and vertical directions (for horizontal machines).
Plotting the condition as a single point on an X-Y graph provides a true indication of the alignment status. The offset and angle information is intended to be used as an alignment tolerance only (to determine how close the alignment is based upon the last set of alignment readings); do not use these data to align the machines. For this reason, offset and angle are always displayed as positive numbers. The curves at the lower left are the tolerances to shoot for.
Tolerance Example Angle (mils/inch) 0.50 Acceptable 0.25 Excellent 1 2 3 Offset (mils) Tolerance Chart (2000 to 3500 RPM) The chart above shows the Angle and Offset for a machine that operates at 2000 – 3500 RPM plotted together. A pure angle reading of 0.45 Mils/Inch and a pure Offset reading of 2.5 Mils are marked by the arrows. These readings are clearly in the acceptable range when looked at individually. However, look what happens when these two “acceptable” reading are plotted together.
Jackshaft One of the biggest advantages in using a laser system is the ability to align over long distances (> 20”). The further apart the sensor heads are mounted, the less practical it is to use the Offset and Angle Tolerances. In those cases, the Jackshaft Tolerances should be used. This method measures the two angles (α and ß) as shown in the figure below. The combination of these two angles are laid out on a graph similar to the offset and angle graphic.
Additional Data Detail 4 For users who want to view the acquired data in more detail, pressing the Page Down key when the dual plot is displayed (see “Dual Tolerance Plot” on page 5-28) will access additional screens. Sine Fit – When Dual Pass or one of the sweep methods is used, the dual Sine Fit screen is displayed first. Points which are shown as boxes have been included in the fit to the sine curve. How well these points fit the sine curve is given as a percentage.
5 CSI does not recommend making moves based on sine fit percentages of less than 70%. Although sine fits of 70 to 85% can be used, CSI recommends another set of readings be made to try and improve the accuracy. Sine fits above 90% provide the highest repeatability. Note Although up to 180 data points can be acquired, not all the data points are fit to the sine curve. The data points fit to the sine curve (up to a maximum of 36) are selected so they are evenly spaced over the acquired sweep area.
From the dual Sine Fit screen, press Enter to leave this screen and display the Sine Fit Status screen. 6 Sine Fit Status Screen Sine Fit Status – this screen summarizes the number of points used, percentage of fit, and lists factors (errors) which could be corrected to improve the data. From the Sine Fit Status screen, press Enter to leave this screen and display the View Data Screen.
4 Point - View Data – this screen appears first if using the 4 point methods or immediately following the sine fit information if using the sweep methods. Data cannot be edited and is simply provided for the convenience of those who are accustomed to recording the data in this manner or who wish to use this data to perform a graphical solution on paper. To see the “raw data,” (the position of the beam on each target) press the 0 key. To return the top reading to zero, press the 0 key again.
Horizontal Log – press the Enter key to exit the vertical log and display the horizontal. The arrow keys perform the same cursor and scaling functions as for the vertical plot. Pressing Enter at this screen returns to the program’s main menu.
10 To view the Acceptable and Excellent tolerances, press the Alt and Page Up keys. To view all the reading sets at the optimum scale, press the Alt and Page Down keys. To increase or decrease the scale by a factor of two, press the Up and Down arrow keys. Horizontal Log Display Once you have reached the tolerance targets, your machinery should operate correctly without any adverse effects from misalignment.
Storing Data Sets From View Data the alignment readings and machine moves will be automatically recorded and stored when the Enter key is pressed to exit from either the dual tolerance plot or the Horizontal Log screen if viewing additional data details. This step returns you to the program’s Main menu. When the readings and moves are recorded, a screen listing the number of readings recorded for the current alignment job will appear for a few seconds.
Machine Moves After defining the job, checking the foot pre-check, collecting alignment data, and viewing the analysis of the alignment data, you are ready to see what machine moves are required. This section shows the screens and information that are available. While in the Machine Moves section, in addition to viewing the required corrections, you can watch them being made in live mode (and view six different solutions in each plane – horizontal and vertical).
Vertical Move 5-42 Using UltraSpec Alignment - General Overview
One of the six screens shown on the previous page (side view) will be displayed when entering the Machine Move section. Each screen shows a separate solution to bring the equipment into alignment. Solutions are expressed in mils or millimeters and show the direction the equipment should be moved. To select the screens, press the Left/Right Arrow to toggle through them. Except for first reading sets, all the screens default back to the solution arrangement they were in when last used.
Horizontal Move 5-44 Using UltraSpec Alignment - General Overview
One of the six screens shown on the previous page (top view) will be displayed when entering the Horizontal Move section. Just like the Vertical move section, each screen shows a separate solution to bring the equipment into alignment. Solutions are expressed in mils or millimeters and show the direction the equipment should be moved. The target indicates how close the machine horizontal or vertical positions are to being in tolerance. The center (bullseye) indicates an excellent range.
Warning! Do not change the rotational position after is pressed. This will cause the move to be incorrect. Warning! Do not loosen the machine feet hold down bolts until after you have entered Live mode (after the Delete key has been pressed). Loosening the hold down bolts prior to entering Live mode can cause the move to be incorrect. Note The angular position information of the laser heads is shown to the right of the machines.
After the fixtures are in the chosen rotational position, press the Delete key to start the live mode, and then move the machine(s) until they are within tolerance. Live Mode active with machine position more than 2 x out of acceptable tolerance Live Mode active with machine position more than 1 x but less than 2 x out of acceptable tolerance Warning! When the machine(s) are within tolerance, before exiting the Live mode, tighten the machine hold down bolts.
Warning! Do not use a hammer to move machines. These impacts may move either sensor head, causing improper machine positioning. CSI recommends that you use jack bolts (permanent or portable).
If a live move is done in the vertical direction, if you go directly to the Horizontal Move screen (or visa versa) and press the Insert key to start the Live Mode, the following message will be displayed. 13 Once a live move is done in either the vertical or horizontal direction, a second live move should not be done in the opposite direction without first acquiring a new set of laser readings.
5-50 Using UltraSpec Alignment - General Overview
Chapter 42 6 Acquiring Alignment Data Data Collection Methods - Overview In this chapter, we will examine each of the modes which can be used for acquiring alignment data for the purpose of shaft alignment. It is assumed that you have previously read the chapter “Using UltraSpec Alignment General Overview” on page 5-1. Therefore, this chapter does not explain the various functions such as Job Definition and Soft Foot analysis which are common to all modes.
When using the 4 point methods, ideally, the sum of the two horizontal measurements will equal the sum of the two vertical measurements. This relationship may be used to check the data for validity. Any variance greater than 10-20% is a cause for concern. When this occurs, repeat the readings to verify that a variation wasn’t accidentally introduced by the user. For example, by using the fixtures as levers to turn the shaft or by not controlling the torsional play in the coupling.
When using the sweep mode calculations are completed in the following manner. If readings were taken from each laser target at 1° intervals (with the position as the Y- axis and the rotational position as the X-axis), a sine wave would be formed. Even when only part of the sine wave is completed, UltraSpec Alignment software can complete the remainder of the curve. Called curve fitting, all values used to determine the machine moves can be obtained from the completed sine waves.
Quick Spec This option is set in the Alignment Setup menu and is accessed by using the Options key. When set to Yes, Quick Spec works with any selected shaft alignment method to give an abbreviated means of checking whether the machine alignment is in tolerance. If the machine alignment is unacceptable, you can provide additional machine dimensions and continue as a normal alignment. Note Refer to “Quick Spec” on page 6-33 for additional information about using Quick Spec.
Auto Sweep Since they have built-in inclinometers, CSI’s laser fixtures allow data to be automatically acquired while the shaft is rotated. The arc of rotation can vary from as little as 45° to a full 360° (one revolution). This mode is especially useful when the 4 point measurement technique is impractical or when inconsistencies in shaft position exist at points in the rotation.
Standard - this mode of operation (sometimes referred to as the Unidirectional Mode) is the mode that is most often used during Auto Sweep alignments. In this mode, a direction of rotation is automatically defined for data acquisition based on the first rotation to progress past the starting point by 20 degrees. In the Standard Mode, data acquired in the Data Acquisition Direction of Rotation will always overwrite any previous data stored at the same angular position.
Averaging - this mode of operation is intended to allow multiple sampling of data in order to reduce the noise in the data by averaging all of the acquired values. In the Average Mode, a Data Acquisition Directions of rotation is defined in the same manner as it is in the Standard Mode.
The current alignment method is always shown at the bottom center of the main menu. Once the job has been defined and any soft foot has been corrected (if necessary), prepare to measure the misalignment by selecting Alignment Data from the Main Menu. 1 With Alignment Data highlighted, press the Enter key to start the data acquisition procedure. The following screen will be displayed.
Note For the greatest accuracy and repeatability, all readings should be acquired using the same direction of rotation. In addition, it is best to use the same direction of rotation as the machine normally operates. 3 The 8215/8225 laser fixtures are designed to be rotated a full revolution in two seconds. As with any sweep, a smooth, uniform acceleration and deceleration during the rotation of the laser heads is necessary for accurate, reliable, and repeatable data.
When the data transfer is complete, an Analysis in Progress screen similar to the following is displayed while the data is curved to fit a sine wave. If the fit is satisfactory (85% and above), you are returned to the main menu where the data may now be viewed. 5 6 Otherwise, you are warned that the data is “Unfit” (less than 85%). At this point you should either repeat the data acquisition or try to manually condition or edit the data.
If you do encounter a machine where this becomes a problem too great to overcome, consider switching to an alternative method such as Manual Sweep or 4 Point Auto.
Manual Sweep Manual Sweep functions similarly to the Auto Sweep mode except that the laser heads, or shafts, are stopped at each position where data is to be taken and a key pressed to store a reading. Data from up to 36 positions may be recorded. This mode is especially useful for performing uncoupled or nonrotational alignments. This is the recommended sweep method for sweeps that are <75º. The current alignment method is always shown at the bottom center of the screen.
After the job has been defined and any soft foot condition corrected (if necessary), select Alignment Data to acquire a new set of shaft readings. 7 The current laser readings are shown in reverse video just below the screen title line. The current laser head position is shown graphically by a heavy black line on the circles and numerically by the degree readings at the bottom of the screen.
. 9 Note A minimum of three data points over a 45º sweep arc is required, but CSI recommends a minimum of 8 data points (samples) acquired over a sweep arc of at least 90º. When all the desired samples (36 max.) have been acquired, press the Enter key to accept the data. An “Analysis In Progress” screen similar to the following is displayed while the data is curve fit to a sine wave. If the fit is satisfactory (85% and above), you are returned to the main menu where the data may now be viewed.
Otherwise, you are warned the data is “Unfit” (less than 85%). At this point you should either repeat the data acquisition or try to manually condition or edit the data. This built-in check helps alert you to the data losing reliability in the misalignment calculations. Refer to “Additional Data Detail” on page 5-34 for more information. Note For the greatest accuracy and repeatability, all readings should be acquired using the same direction of rotation.
If you do encounter a machine where this becomes a problem too great to overcome, consider switching to an alternative method such as 4 Point Auto. 4 Point Auto The 4 Point Auto method is a more traditional style of acquiring data for alignment. The laser heads are mounted on a shaft, and the shaft is then rotated so that data can be taken when the laser heads are at the 12 o’clock (0 or 360°), 3 o’clock (90°), 6 o’clock (180°), and 9 o’clock (270°) positions.
After the job has been defined and any soft foot condition corrected (if necessary), select Alignment Data to acquire a new set of shaft readings. The current laser readings are shown in reverse video just below the title line of the data acquisition screen.
Data Acquired at 12 O’clock (270°) Data Acquired at 3 O’clock (0°) Data Acquired at 6 O’clock (90°) 6-18 Acquiring Alignment Data
Data Acquired at 9 O’clock (90°) When all the data has been acquired all the desired points, press the Enter key to accept the data. At this point the data is checked for validity (refer to “Data Quality” on page 5-27 for more information). If the data validity is satisfactory, you are returned to the main menu where the data may now be viewed. Otherwise, you are warned that a data validity error exists. At this point you should either repeat the data acquisition to check for accuracy.
Note Remember, when shaft movement due to causes other than misalignment is present in the data this will appear as a randomness (noise) in the data. This is not normally a problem when the misalignment great, but will increasingly interfere as the misalignment decreases. Therefore, the better the alignment the more likely the chance of seeing the data validity warning.
4 Point Manual The 4 Point Manual method is similar to the 4 Point Auto mode except that the user has complete control over when data is acquired and which of the four measurement positions it will be used in. This mode is useful when the machinery is not mounted in a true horizontal orientation, so that the inclinometer is not effective, or when the clock positions relative to vertical and horizontal base movements of the machine are nonstandard.
The current laser head readings are shown in reverse video just below the title line of the display. The current head angle is shown at the bottom center of the screen. To acquire data, use the arrow keys to move the reverse video of the data point to be acquired to the desired position. When using this mode the user must be very careful to get the desired readings into the desired positions. That is why this is called the 4 Point Manual method.
Note CSI does not recommend using only three readings if four are available. At this point the data is checked for validity (refer to “Data Quality” on page 5-27 for more information). If the data validity is satisfactory, you are returned to the main menu where the data may now be viewed. 13 Otherwise, you are warned that a data validity error exists. At this point you should either repeat the data acquisition to check for accuracy.
Note Remember, when shaft movement due to causes other than misalignment is present in the data this will appear as a randomness (noise) in the data. This is not normally a problem when the misalignment great, but will increasingly interfere as the misalignment decreases. Therefore, the better the alignment the more likely the chance of seeing the data validity warning.
Dual Pass Dual Pass functions similar to the Auto Sweep mode except data is automatically acquired as each laser head passes by each other. This mode, like Manual Sweep, is useful for performing uncoupled or non-rotational alignments. In this mode of operation, PSD and angle data are only taken when the laser beam of each laser head enters the “valid data” window centered on the vertical centerline of the other head’s PSD.
To acquire data using the Dual Pass method, you must first select Dual Pass as the method from the Alignment Setup menu (accessed by pressing the Options key). Once this method is shown, using the Up/Down Arrow keys to select and the number keys on the keypad to toggle the selection, set the Target Window percentage. • Target Window - determines the size of the valid data window around the vertical centerline of the other laser head's PSD.
The following scenario will more clearly illustrate how the Dual Pass method operates. 1. ··· When the analyzer initializes the laser heads, all data is cleared and they enter the “Dual Pass” mode of operation. 2. ·· The laser heads then begin detecting the presence of the other laser head’s laser beam on its PSD. If a laser beam is not on a PSD, the laser head's LED will be flashed solid yellow. 3.
The typical method of operation will be for the user to initialize the laser heads with the analyzer. One of the heads will then be moved to a new position. Then the second head will be moved past the first head to a new position. As the laser heads pass each other, the data will be acquired. The first head will then be moved past the second head to a new position. Again, as the laser heads pass each other, both laser heads will acquire the data.
With Alignment Data highlighted, press the Enter key to start the data acquisition procedure. The following screen will be displayed. 15 The next screen directs you to turn on the laser heads, position them at any angular position you desire to start from, and then press the Enter key to initialize the laser heads. It is not required to define a sweep arc range and direction of rotation with the Dual Pass mode since this is a type of Manual Sweep mode of operation.
Note For the greatest accuracy and repeatability, all readings should be acquired using the same direction of rotation. In addition, it is best to use the same direction of rotation as the machine normally operates. 16 The 8215/8225 laser fixtures are designed to be rotated a full revolution in two seconds. As with any sweep a good smooth uniform acceleration and deceleration during the rotation of the laser heads is necessary for accurate, reliable, and repeatable data.
When the data transfer is completed, an “Analysis In Progress” screen similar to the following is displayed while the data is curve fit to a sine wave. If the fit is satisfactory (85% and above), you are returned to the main menu where the data may now be viewed. 18 19 Otherwise, you are warned the data is “Unfit” (less than 85%). At this point you should either repeat the data acquisition or try to manually condition or edit the data.
Note Remember, when shaft movement due to causes other than misalignment is present in the data this will appear as a randomness (noise) in the data. This is not normally a problem when the misalignment great, but will increasingly interfere as the misalignment decreases. Therefore, the better the alignment the more likely the chance of seeing the Unfit data warning.
Quick Spec Quick Spec allows you to make a quick check of the alignment condition of a machine with minimal setup and effort. If a machine is found to have unacceptable alignment, the procedure can be readily converted to a full alignment procedure and machine moves calculated. Quick Spec is only available in Pro Align and Pro Align Plus. To use Quick Spec, select the desired alignment method from the Alignment Setup menu which is accessed using the Options key. Then, set Quick Spec to Yes.
Quick Spec Mode Flow Diagram Laser Configuration Dimensions Acquire Data Clear Data View Data Action Take More Data Save Data Define Job 6-34 Align Machine Change Job to Standard Alignment Procedure Acquiring Alignment Data
20 To check the current alignment condition of a machine, mount the laser heads on the shafts, then change the display to match the head positions using any number key to toggle the relative positions. The laser heads are designated as A and B (this is marked on the face plates). 21 Once the head positions have been designated, press Enter to accept. You must now enter the machine speed and two dimensions.
Note In this example, Quick Spec uses the Auto Sweep method to acquire data. 22 The next screen directs you to turn on the laser heads, position them at any angular position you desire to start from, and then press the Enter key to initialize the laser heads. It is not required to define a sweep arc range and direction of rotation due to the increased number of data readings acquired every 2 degrees and the process, which automatically defines the direction of rotation.
Note For the greatest accuracy and repeatability, all readings should be acquired using the same direction of rotation. In addition, it is best to use the same direction of rotation as the machine normally operates. 23 The 8215/8225 laser fixtures are designed to be rotated a full revolution in two seconds. As with any sweep a good smooth uniform acceleration and deceleration during the rotation of the laser heads is necessary for accurate, reliable, and repeatable data.
When the data transfer is completed, an “Analysis In Progress” screen similar to the following is displayed while the data is curve fit to a sine wave. If the fit is satisfactory (85% and above), you are shown the results by means of a dual tolerance plot screen. 25 26 Note For users who want to view the acquired data in more detail, pressing the Page Down key when the dual tolerance plot is displayed will access additional screens. Refer to “Additional Data Detail” on page 5-34 for more information.
Note Remember, when shaft movement due to causes other than misalignment is present in the data this will appear as a randomness (noise) in the data. This is not normally a problem when the misalignment great, but will increasingly interfere as the misalignment decreases. Therefore, the better the alignment the more likely the chance of seeing the Unfit data warning.
Saving Quick Spec Data – if you want to save this data and the job, select “Store Data.” 28 The Define Job screen will then be displayed. 29 A Job # must be supplied before storing the job. You can also add other descriptive information (identifying the machine) at this time, if desired. If this Quick Spec job was recalled from the stored job area, the previously entered data will be present. After all changes to this screen are complete, press Enter to save the job.
30 Press Enter to continue and return to the initial Quick Spec Screen. 31 Using Quick Spec data to align a machine – selecting Align Machine takes you directly into the normal alignment mode. To return to Quick Spec, simply clear the current job. If you wish to calculate the moves, then complete the job definition and go directly to the Machine Moves selection. Note If soft foot has not been corrected previously on this machine, you will want to check for soft foot before making any moves.
6-42 Acquiring Alignment Data
Chapter 14 7 Straightness Application Overview The straightness feature found in the UltraSpec analyzer alignment application is used to determine surface profiles. This profile can be of a motor baseplate or checking the crown on a rolling application. You must use a set of laser sensor heads and mounting fixtures (CSI model 8AA50) to acquire surface profile readings.
Select the Application To select the straightness method of data collection, the UltraSpec analyzer must be in the alignment application. Press the Utility function key and press the Enter key when the selected application is highlighted. Note If already in the alignment application, this step and the next are not required. The following screen is displayed. 2 Select PRO ALIGN PLUS and press the Enter key.
Alignment Setup 3 From the alignment application's main menu, press the Options function key. Arrow the selection bar to Alignment Setup and press the Enter key. The following screen is displayed. 4 Use any Number key to toggle through the selections for method until straightness is displayed. Once this method is shown, use the Up and Down Arrow keys to make a selection, and any Number key to toggle through the options for that selection.
• Collection Mode – select Standard for a continuous reading of the Laser Readings (the current or last reading is used), or select Average for a continuous accumulative average of the laser readings. The straightness method main menu will now be displayed. 5 Highlight Job Definition, and press the Enter key. Note Notice that the method (straightness) is shown at the bottom, center.
Defining the Job 6 On this screen, enter the requested information using the alphanumeric keypad. Note All the information is required for proper job documentation. Press the Enter key when the information has been filled in.
Four Ways of Configuring the Laser Fixtures There are four ways to configure the laser fixtures. The first consideration is which fixture is to be fixed and which one will be moved. The configuration shown below is for the left fixture to be fixed. Notice the laser head to be used at each location can also be selected. 7 The other two configuration options are shown below. This arrangement has the right fixture fixed.
Entering Distances 9 After the job definition step has been completed, an “X” is placed beside that step indicating it has been completed. With Distances highlighted, press the Enter key. The following screen is displayed. 10 Enter the distance (in inches) between the fixed head and the first measurement location. To add additional measurement segments, press the Up arrow key. The distance between the segments can be different lengths and up to 50 segment measurements can be taken.
The distance screen will show up to four measurement locations at one time. Notice that a total of eight measurement segments have been defined in this example and the first segment field is active. This information is displayed on the overall graph below the segment fields. The arrow shows the present location. 11 Help Messages Help messages are available in any of the UltraSpec applications by pressing the Help function key.
Taking Straightness Data 13 Again, an “X” has been placed in Step 2 showing completion. Highlight Step 3, Straightness Data, and press the Enter key. The following screen is displayed.
Turn the lasers on. To disable the sleep mode on each laser head, hold the power button down for 3 seconds, until the activity LEDs are both off. Laser communications with the moveable head must be established to collect data at the defined segments. Communication can be with radio frequency (RF) or cable. Start at the farthest point and center both lasers. To accept the value displayed, press any number key. Use the Up arrow key to move to the next segment to the right.
View Data 15 Once all the readings are taken, press the Enter key to accept all the data. Step 3 has an “X” showing completion and step 4 is highlighted. Press the Enter key to view the results of the profile. 16 The surface profile for the eight segments measured is displayed. A cursor can be moved using Left or Right arrow keys to display information on an individual segment. The segment number, length, measured value and height from the laser (dotted line) is shown on the bottom.
17 An “X” now appears next to step 4 indicating completion of the current straightness job. To save the current job information press the Options function key. The following screen is displayed. 18 Choose Store Job and press the Enter key.
If no duplicate job numbers were previously stored, the screen below will be displayed. 19 You can now transfer the job data to UltraMgr for long-term storage. Note For additional information on storing a job, recalling a job, and deleting a job refer to “Options Key” on page 3-2 for details. For information on printing, refer to “Screen/Print Key” on page 3-25 for details.
7-14 Straightness Application
Chapter 8 Page 1 Friday, January 26, 2001 10:34 AM Chapter 8 8 Application Information Machinery Shaft Alignment – General Overview Poor shaft alignment can cause the following problems: • Bearing failure • Shaft deflection fatigue • Seal leakage and failure • Coupling failure • Internal heating • High energy consumption • Excessive vibrations (studies have shown that almost 50% of excessive vibration in direct-coupled rotating equipment is due to misalignment) Proper machine alignment will result in:
Chapter 8 Page 2 Friday, January 26, 2001 10:34 AM • Documentation of work done for use in future alignment jobs Early alignment methods involved using a straightedge along the coupling rims. This is still a good procedure to use as a preliminary step. In fact, for low speed machines, operated infrequently for short periods of time, it may be all that is needed. However, more complex machines require more than this.
Chapter 8 Page 3 Friday, January 26, 2001 10:34 AM Alignment Application Notes To achieve ideal machine alignment, the shaft centerline of one machine element (such as a motor) must coincide with the centerline extension of another machine shaft (such as a pump) during operation. In more complex applications, three or more elements may be aligned in a train. Misalignment can occur both horizontally and vertically.
Chapter 8 Page 4 Friday, January 26, 2001 10:34 AM Pre-job Preparation and Setup Before starting any alignment job, the history of alignments performed on this machine(s) should be reviewed. Were any special problems found during the previous alignment; if so, what were they (soft foot, piping strain, coupling problems, etc.
Chapter 8 Page 5 Friday, January 26, 2001 10:34 AM Proper Foundation On new installations, allow foundation concrete to cure sufficiently before installing your machines. Normally, you should not mount machines directly on the foundation. Base plates usually provide more stability. Also, to make future alignments easier, a set of high quality (stainless steel, etc.) pre-cut shims should be placed beneath each foot. These should be at least 1/8 inch (3 mm) thick.
Chapter 8 Page 6 Friday, January 26, 2001 10:34 AM Thermal Growth Unfortunately, machines that must be aligned may not expand thermally at the same rate. Because of this, you may have to intentionally misalign them in their “cold” positions in order to achieve alignment when they are “hot”. The following drawing shows an example of this.
Chapter 8 Page 7 Friday, January 26, 2001 10:34 AM Alignment Pitfalls Some pitfalls to good alignment are: • Improperly or not correcting for soft foot • Thermal growth • Excessive shaft play or radial clearances • Bent shafts • Damaged bearings • Torsional play Alignment Pitfalls 8-7
Chapter 8 Page 8 Friday, January 26, 2001 10:34 AM UltraMgr UltraMgr is a versatile, PC-based, database software package that is used to manage corrective technologies data. UltraMgr is designed to communicate with the UltraSpec analyzer and other CSI analyzers. The storage of alignment information in a database provides many advantages which include: • The ability to quickly retrieve and review the alignment status of all equipment in an entire plant to help plan the maintenance priorities and scheduling.
Chapter 22 9 System Maintenance and Troubleshooting Overview In this chapter, for your convenience, we have grouped many of the various activities related to maintaining and troubleshooting the UltraSpec Laser Alignment system. In some cases, the actions are also discussed in other parts of the manual. CSI hopes this will help you quickly find maintenancerelated information when you need it.
UltraMgr Software and Prerequisites In order to use the UltraSpec 8215/8225 compatible 2.40 applications with UltraMgr compatible software, the software must be RBMware version 4.40 or later for Windows. DOS UltraMgr software and earlier versions of Windows UltraMgr software will not work with the UltraSpec 8215/8225 compatible analyzer 2.40 or later applications. Note The UltraSpec Thermal Growth application will note communicate with the UltraMgr software.
Precautions Please follow these precautions carefully. Any product damage due to these conditions may void the warranty. • Do not change the battery pack with the battery charger connected as damage may occur to the analyzer. • Use only CSI-supplied battery chargers that have been approved for use with the UltraSpec analyzer and 8215/8225. The use of any other charger will most likely damage the equipment.
UltraSpec Analyzer Battery Maintenance UltraSpec Analyzer Battery A rechargeable battery pack is used to power the UltraSpec analyzer. Before using the analyzer, verify that the battery has enough charge to operate properly. The battery needs to be recharged if: • The analyzer will not power up; or • The analyzer displays a low battery warning and turns itself off.
Battery Test The Battery Test function will give an approximate indication (in percent) of the battery’s condition and the battery pack voltage. To access this function, select Battery Test from the Utility key menu. UltraSpec 8000 UltraSpec 8117 This display presents approximate values and should only be used as a guideline in determining the amount of battery charge remaining.
Note If the analyzer should display the low battery warning screen and turn itself off, the analyzer’s memory will remain intact for approximately two weeks. Therefore, the collected data are retained in memory and can be accessed after the analyzer’s battery has been recharged. UltraSpec 8000 Analyzer Battery Recharge To recharge the battery, set the “Trickle/Fast” switch on the underside of the Model A2115-C battery charger to “Fast.
Changing the UltraSpec 8000 Analyzer Battery Removing the Battery To change the battery pack: 1. Insure that the analyzer is Off, and that the battery charger is not connected to the analyzer. 2. Remove the two screws on the sides of the analyzer located just above the bottom edge (not the screws on the bottom cover), and remove the bottom cover. 3. Carefully remove the battery pack from the analyzer case, and disconnect the 3-pin connector. 4.
Note If the battery is hard to pull out, you may have to remove the front cover of the analyzer. To do so, carefully slide the cover downward until the cable connector is exposed. Disconnect the cable and slide the cover on down until the battery is free. After replacing the battery, reverse the process by sliding the cover back up until the cable can be re-attached. Continue by returning the cover to its original position.
UltraSpec 8117 Analyzer Battery Recharge To recharge the battery, plug the Model 93140 charger into a standard 115 VAC outlet, and then plug the charger jack into the battery charger input located on the top panel of the UltraSpec 8117 analyzer. to AC wall outlet power supply AC Power Adaptor 1 The supplied battery charger will completely recharge the battery pack in 14 to 16 hours.
Changing the UltraSpec 8117 Analyzer Battery To change the UltraSpec 8117 analyzer’s battery pack: 1·····Make sure that the analyzer is Off, and that the battery charger power supply is not connected to the analyzer. 2·····On the bottom of the analyzer, remove the two screws on the bottom panel as shown below. Then remove the panel. 2 3·····Using the tabs on the sides of the battery pack, carefully remove the battery pack from the battery compartment.
strip contacts 4 5···· Tuck the battery pack tabs into the case on the sides of the battery pack. Make sure that the tabs do not interfere with the installation of the bottom panel. 6···· Replace the bottom panel and screws. Caution! Do not change the battery pack with the battery charger connected as damage may occur to the analyzer. See “Using the Model 8211 and Model 8212 Battery Chargers” on page 9-14 for information about recharging batteries using the 8211 battery charger.
8215/8225 Fixtures General Maintenance Care and Handling To ensure satisfactory service from this system, follow these procedures: • Keep the mounting base and chain mounting posts lightly oiled to prevent them from corroding. • To maintain repeatability and accuracy, avoid dropping fixture items. Refer to the Customer Assistance section for repair, update, and calibration. • Do not subject system items to large temperature swings. • Do not engrave on the sensor heads.
Conditions That can Cause Problems With the 8215/8225 Water vapor or dust can interfere with a target “seeing” its laser. The air between the sensor heads should be visually clear. Take care to ensure that the air between the laser heads is not being heated from steam leaks, uninsulated piping, etc. Heated air rising within the span between the sensor heads can refract the laser beams and cause errors in the alignment readings. Operate the 8215/8225 fixtures at ambient temperatures.
Using the Model 8211 and Model 8212 Battery Chargers Battery Charging Batteries may be charged with the Model 8211 or the Model 8212. The Model 8211 is a “smart, drop-in” charger that can provide a fast- or tricklecharge for the laser heads and analyzer. In fact, it can discharge the laser heads, if necessary. The Model 8212 is an “overnight” trickle-charger that can only trickle-charge laser heads and the analyzer.
Model 8211 Smart Charger The Model 8211 provides all battery charging needs and comes with the system. It is a “smart, drop in” charger for the laser heads; it will also charge the analyzer when plugged into a cable. The following picture shows both of the laser heads and the UltraSpec analyzer being charged. Charging the Sensor Heads and Analyzer with Model 8211 Charger To set up the 8211, complete these steps: 1.···· Plug the power cord into the power supply. 2.
Charging the Sensor Heads with the Model 8211 Place the sensor heads over the posts so that the heads face outward as shown in “Charging the Sensor Heads and Analyzer with Model 8211 Charger” on page 9-15. Heads can be charged individually or together.
Warning! Note that if the battery is fully charged, a user is able to initiate fast charge by pressing the “Fast” button. After about 2 minutes, the charger will stop fast charge in this case. However, to avoid overcharging batteries, you should not press the “Fast” button with an already fully charged battery. After the “Fast” charging cycle has completed the charger beeper will sound and automatically begin trickle charging.
Note After power has been applied to the charger and the sensor head have been placed in it, if none of the LED's for that sensor head are lit then the contact between the sensor head and charger may not be sufficient enough to charge the batteries. No LED's lit indicates a “no battery present” state. If this occurs, remove the sensor head from the charger and try reseating it back into the charger. Note After a charging cycle has begun, if that charging cycle is interrupted (e.g.
Charging the UltraSpec 8000 Analyzer with the Model 8211 Plug the charging cable (A821101) from the bottom end cap on the 8211 (earlier than Rev. 4) into the top of the analyzer. TRICKLE mode will start the charge cycle. To change to FAST mode, press the FAST button in the Analyzer section. The analyzer battery is not monitored but utilizes a timer to avoid overcharging. The 8211 will charge the analyzer in FAST mode for 15 hours or until the FAST button is pressed again (whichever comes first).
Model 8212 Trickle Charger The Model 8212 battery charger is a trickle charger for the laser heads and the Model 8117 UltraSpec analyzer. It will charge the laser heads and analyzer in ten hours. This is intended to be an overnight charge. The laser heads should not be left on charge over 24 hours. Continual overcharging the batteries will result in a shortened life. To set up the Model 8212 charger, complete the following steps: 1.
Charging the Model 8117 and 2120 Analyzers with the Model 8212 Charger After plugging the charging cable (A821102) into the 8212, plug the other end of the cable into the charger connection on the top end cap of the Model 8117 or the Model 2120 analyzer. Ensure the LED on the analyzer illuminates, if applicable. The Model 8117 battery pack will recharge in 14 to 16 hours. If the batteries are allowed to continually remain on charge for longer than 16 hours, battery degradation will occur.
To conserve battery life, the 8215/8225 has a sleep mode and a shutdown mode. The sleep mode is activated after 5 minutes of no communication with the analyzer. In the sleep mode, the laser beam and RF communication are shutdown until communication is reestablished. All data in memory is saved. In the auto-shutdown mode, the sensor heads are completely shutdown. The Power button will start the sensor heads again. All data in memory is lost, therefore another sweep should be taken.
