Emerson 2130 RBM Consultant Pro Reference Manual

Reference Manual

2130 RBM Consultant Pro

Laser Alignment

Analyzer and Fixtures

®

Part # 97191 Rev. 1

Copyright

© 2007 by Emerson Process Management.

All rights reserved.

No part of this publication may be reproduced, trans­mitted, transcribed, stored in a retrieval system, or
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This manual is provided for informational purposes.

EMERSON PROCESS MANAGEMENT MAKES NO WAR-

RANTY OF ANY KIND WITH REGARD TO THIS MATERIAL,

NCLUDING, BUT NOT LIMITED TO, THE IMPLIED WAR-

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RANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-
TICULAR PURPOSE. Emerson Process Management shall

not be liable for errors, omissions, or inconsistencies
that may be contained herein or for incidental or con­sequential damages in connection with the furnishing,
performance, or use of this material. Information in this
document is subject to change without notice and does
not represent a commitment on the part of Emerson
Process Management. The information in this manual is
not all-inclusive and cannot cover all unique situations.

Product Support

Should you have any comments on this documentation
or questions concerning the Agreement on the fol­lowing pages, please contact Emerson Process Manage­ment’s Product Support Department.

Addresses:

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AMS Machinery Manager Reference Manual

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iii

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CSI uses the latest virus checking technologies to test all
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Hardware Technical Help

1. Please have the number of the current version of
your firmware ready when you call. The version
of the firmware in Emerson Process Management’s
CSI 2100 series, CSI 2400, and other analyzers
appears on the power-up screen that is displayed
when the analyzer is turned on.

2. If you have a problem, explain the exact nature of
your problem. For example, what are the error
messages? When do they occur? Know what you
were doing when the problem occurred. For
example, what mode were you in? What steps did
you go through? Try to determine before you call
whether the problem is repeatable.

Hardware Repair

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hardware products free for one year from the date of
purchase. This service warranty includes hardware
improvement, modification, correction, recalibration,
update, and maintenance for normal wear. This service
warranty excludes repair of damage from misuse,
abuse, neglect, carelessness, or modification performed
by anyone other than Emerson Process Management.

After the one year service warranty expires, each return
of a Emerson Process Management hardware product is
subject to a minimum service fee. If the cost of repair
exceeds this minimum fee, we will call you with an esti­mate before performing any work. Contact Emerson
Process Management’s Product Support Department for
information concerning the current rates.

Export Restrictions

You agree to comply fully with all laws, regulations,
decrees and orders of the Unites States of America that
restrict or prohibit the exportation (or re-exportation) of

iv

Obsolete Hardware

Although Emerson Process Management will honor all
contractual agreements and will make every effort to
ensure that its software packages are “backward com­patible,” to take advantage of advances in newer hard­ware platforms and to keep our programs reasonably
small, Emerson Process Management reserves the right
to discontinue support for old or out-of-date hardware
items.

Software Technical Help

1. Please have the number of the current version of
your software ready when you call. The version
number for software operating under Windows
displayed by selecting “About” under the Help
menu bar item.

2. If you have a problem, explain the exact nature of
your problem. For example, what are the error
messages?

message.)

(If possible, make a printout of the error

When do they occur? Know what you
were doing when the problem occurred. For
example, what mode were you in? What steps did
you go through? Try to determine before you call
whether the problem is repeatable.

3. Please be at your computer when you call. We can
serve you better when we can work through the
problem together.

®

is

Returning Items

1. Call Product Support (see page 2) to obtain a return
authorization number. Please write it clearly and
prominently on the outside of the shipping
container.

2. If returning for credit, return all accessories
originally shipped with the item(s). Include cables,
software diskettes, manuals, etc.

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returning the item(s).

4. Insure your package for return shipment. Shipping
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responsibility. 7COD packages cannot be
accepted and will be returned unopened.

Software Technical Support

Emerson Process Management provides technical sup­port through the following for those under support
agreement:

• Telephone assistance and communication via the
Internet.

• Mass updates that are released during that time.

• Interim updates upon request. Please contact
Emerson Process Management Product Support for
more information.

v

vi

Contents

How To Use This Manual · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-1

Emphasis Paragraphs · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-5
Analyzer Serialization· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-5
UltraMgr Software and Prerequisites · · · · · · · · · · · · · · · · · · · · · · · · · 1-6

Standard Equipment · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-7

Fixtures Case Layout (bottom section) · · · · · · · · · · · · · · · · · · · · · · · · 1-7
Fixtures Case Layout (top section) · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-8

Chapter 2 • Setting Up and Using Laser Alignment Fixtures

Models 821500 and 822500 RF Laser Systems Only· · · · · · · · · · · · · · · · ·2-4

General Description· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-5

Sensor Head Description· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-5

General Maintenance· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-10

Care and Handling· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-10
Calibration· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-10
Battery Charging · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·2-11

Battery Usage - Laser Heads · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-16

Precautions · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·2-17

Introduction to Laser Alignment Fixtures Setup · · · · · · · · · · · · · · · · · · · 2-18

Attaching the Fixtures · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-19

Attaching the B821007 Carbon Steel Mounting Base · · · · · · · · · · · 2-19
Attaching Chain to the Chain Pickup · · · · · · · · · · · · · · · · · · · · · · · · 2-20
Allowing Maximum Tightening Range · · · · · · · · · · · · · · · · · · · · · · 2-21
Positioning a Mounting Base · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·2-22
Positioning the Other Mounting Base· · · · · · · · · · · · · · · · · · · · · · · · 2-23
Attaching Excess Chain · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·2-24
Using the Chain Clip· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·2-26
Installing a Post · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-27
Mounting a Sensor Head· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-28

Models 821500 and 822500 RF Laser Systems Only· · · · · · · · · · · · · · · ·2-30

Mounting the Other Sensor Head · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-31
Communication Between the Fixtures and Analyzer · · · · · · · · · · · · 2-32
Connecting the 8000RF Interface · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-34

vii

Turn the Laser Beams On· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-40
Center the Laser Beams · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-41
Rough Alignment of the Laser Beams · · · · · · · · · · · · · · · · · · · · · · · 2-42

Introduction to Special Applications · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-46

Using Additional Mounting Blocks· · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-47

Adding a 2-inch (51 mm) Block· · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-48
Mounting One Bracket on a Coupling · · · · · · · · · · · · · · · · · · · · · · · 2-50
Mounting on Shafts (or Couplings) > 8-inch
(203 mm) Diameter · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-51

Using Alternative Mounting Brackets· · · · · · · · · · · · · · · · · · · · · · · · · · · 2-52

Chapter 3 • Horizontal Alignment

Help · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-1
Basic Alignment Steps · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-1

Advanced and Basic Laser Align Applications · · · · · · · · · · · · · · · · · · · · · 3-2

Advanced Laser Align · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-2
Basic Laser Align · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-2

Main Screen · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-3

Three Step Alignment · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-5

viii

Main Screen Function Keys · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-6

Alt Main Screen · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-7

Alt Main Screen Function Keys · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-8

Job Reset· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-11

Basic Mode· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-12

Basic Mode Function Keys · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-13

Job Reset· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-16
Machine Configuration Function Keys · · · · · · · · · · · · · · · · · · · · · · 3-18

Laser Align (Alignment) Method Function Keys · · · · · · · · · · · · · · · · · · 3-20

Tolerance Type · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-22
Tolerance Type Function Keys · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-22
Laser Configuration Function Keys · · · · · · · · · · · · · · · · · · · · · · · · 3-24

Laser Address Selection · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-26

Check Lasers· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-30
Laser Head Status Function Keys · · · · · · · · · · · · · · · · · · · · · · · · · · 3-32
Job Manager · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-34

Job Manager Function Keys · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·3-35
Edit Job Setup · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-38
Edit Job Setup Function Keys · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-39
Job Flow · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·3-42
Job Flow Function Keys · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-43
Enter Dimensions · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-45
Entering Fractions · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·3-51
Quick Spec · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-53
Entering Thermal Growth Information · · · · · · · · · · · · · · · · · · · · · · · 3-56
Growth at Feet· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-57
Growth at Profile· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-59
Gap/Offset · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-64
Face/Rim · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-68
Reverse Dial · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·3-72
Sweep Laser Heads · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-75
Foot Pre-Check · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-76
Foot Pre-Check Function Keys (after the Foot Pre-Check
has been started) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-82
Acquiring Alignment Data · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·3-82
Auto Sweep · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-85
Manual Sweep· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·3-94
Accept Readings key· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-97
Auto 4 Point · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·3-100
Manual 4 Point · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·3-105
Dual Pass· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-111
Dual Pass Cable (8215C2-PM) - Models 821500
and 822500 Only · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·3-119
Review Results · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-121
Review Results (Measurements) Function Keys · · · · · · · · · · · · · · 3-124
Sweep Mode Curve Data · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-126
Data Quality · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·3-127
Move Machine · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-129
Vertical Move · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·3-130
Vertical Move Function Keys · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-132
Horizontal Move · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·3-135
Horizontal Move Function Keys· · · · · · · · · · · · · · · · · · · · · · · · · · · 3-137
Dual Move· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-140
Extra Foot Calculation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-143
Predict Mode · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-145
Prediction Function Keys · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-149
Live Move · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-149

ix

Data Detail (Tolerance Plots) · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-162
Data Detail (Tolerance Plot) Function Keys · · · · · · · · · · · · · · · · · 3-166
Display Sine Fit · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-168
Display Sine Fit Function Keys · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-172
View Data· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-174
C-face Alignment · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-175
Notes· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-180
Notes Function Keys · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-180
Transferring Alignment Job Data and Tolerances · · · · · · · · · · · · · 3-184
Tolerances· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-193

UltraMgr/2130 Laser Align Overview · · · · · · · · · · · · · · · · · · · · · · · · · 3-194

Case Studies · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-195

UltraMgr· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-199

UltraMgr Software and Firmware Prerequisites· · · · · · · · · · · · · · · 3-200
Tolerances· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-201

Chapter 4 • Vertical Alignment

Help · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-3
Basic Vertical Alignment Steps · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-3
Three Step Alignment· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-5
Vertical Main Screen Function Keys · · · · · · · · · · · · · · · · · · · · · · · · · 4-6

Vertical Alt Main Screen · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-7

Vertical Alt Main Screen Function Keys · · · · · · · · · · · · · · · · · · · · · 4-8
Job Reset· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-10
Vertical Machine Configuration· · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-11
Vertical Machine Configuration Function Keys · · · · · · · · · · · · · · · 4-12
Laser Angle Advance · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-13
Laser Angle Advance Function Keys · · · · · · · · · · · · · · · · · · · · · · · 4-14
Vertical Laser Configuration · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-15
Vertical Laser Configuration Function Keys · · · · · · · · · · · · · · · · · · 4-16
Vertical Enter Dimensions · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-17
Define Flange · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-21
Define Flange Function Keys · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-23
Custom Pattern · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-25
Custom Pattern Function Keys · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-27
Vertical Sweep Laser Heads· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-29
Vertical Move Machine · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-38
Angular Move· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-39
Angular Move Function Keys · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-40

x

Offset Move · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-41
Offset Move Function Keys · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-44
Vertical Data Detail (Tolerance Plots) · · · · · · · · · · · · · · · · · · · · · · · 4-45

Chapter 5 • Straightness Measurements

Straightness Main Screen · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·5-3
Three Step Straightness Measurements · · · · · · · · · · · · · · · · · · · · · · · 5-4
Straightness Main Screen Function Keys · · · · · · · · · · · · · · · · · · · · · 5-5
Straightness Alt Main Screen · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-6
Straightness Alt Main Screen Function Keys · · · · · · · · · · · · · · · · · · 5-6
Straightness Laser Configuration · · · · · · · · · · · · · · · · · · · · · · · · · · · ·5-9
Straightness Laser Configuration Function Keys · · · · · · · · · · · · · · 5-10
Straightness Enter Dimensions · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-11
Straightness Move Laser Heads · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-15
Straightness Surface Profile · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-18

Chapter A • Application Information

Alignment Application Notes · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · A-3

Pre-job Preparation and Setup· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · A-5
Changes That Occur During Operation· · · · · · · · · · · · · · · · · · · · · · · A-6

Alignment Pitfalls · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · A-8

Appendix B • Foot Pre-Check Types

Foot Pre-Check Measurement Methods – Soft Foot and
Frame Distortion Index (FDI) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · B-1

Appendix C • Technical Specifications

Mounting Posts (part number D23465) for Alignment Brackets · · · · · · · C-3

Appendix D • Accessories and Optional Products

Optional Items for Laser System· · · · · · · · · · · · · · · · · · · · · · · · · · · · D-1
Other Accessories · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · D-1
Recommended Spare Parts* · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · D-2
Analyzer Travel/Carrying Cases· · · · · · · · · · · · · · · · · · · · · · · · · · · · D-2

xi

Glossary

Index

Batteries/Analyzer Chargers· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·D-2
Alignment Fixtures· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·D-2

Customer Support · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·D-3

Reliability Services· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·D-4

xii

Read This First

Note

How To Use This Manual

This manual is arranged in the following manner:

• Chapter 1 — read this chapter before attempting to use the Model 2130
Laser Alignment program or before proceeding to subsequent chapters.

• Chapter 2 — lists and describes the various components that make up the
laser alignment system.

• Chapter 3 — provides general application overview information about pro­cedures used in horizontal shaft alignment.

• Chapter 4 — provides general application overview information about pro­cedures used in vertical shaft alignment.

• Chapter 5 — describes how to perform straightness measurements.

Chapter

1

• Appendix A — provides general application overview information about pro­cedures used in shaft alignment.

This manual covers information specific to the 2130 RBMConsultant
Pro Advanced Laser Alignment program.

It is assumed that the user is familiar with the general hardware and
operation of the Model 2130 analyzer. If any questions or concerns
arise in using the analyzer, refer to the 2130 RBMConsultant Pro,
Dual-Channel Machinery Analyzer manual (part number 97017).

• Appendix B — provides descriptions of Foot Pre-Check types and their
advantages and disadvantages.

• Appendix C — details the technical specifications for the Model 8215/8225
laser alignment fixtures.

• Appendix D — describes the various accessories and optional products that
are available for use with the Laser Align application.

1-1

Note

In this manual, “8215” and “8225” (sometimes quoted as “8215/
8225”) refer to both the RF versions (Models 821500 and 822500)
and the direct-connect only versions (Models 821501 and 822501 )
laser systems except where information specific to one type of laser
system is discussed.

1-2

Introduction

The UltraSpec Pro 8215/8225 Laser Alignment Fixtures are the latest in a com­plete line of alignment equipment provided by Emerson Process Management.
The 8215/8225 system is used in conjunction with the Model 2130 Laser Align pro­gram. Although the Model 2130 analyzer can be purchased separately, it must be
used to process the data from the fixtures. The Model 8215/8225 system attaches
sensor heads to shafts which are typically coupled. Laser beams are emitted from
each sensor head and targeted on the opposite sensor head. Each shaft position is
measured in relation to the other shaft by rotating the two shafts. Shaft misalign­ment is calculated from the position of each laser beam on its respective target, at a
range of angular positions of the laser heads.

The position of each laser beam on its target transmits from each sensor head to
the Model 2130 analyzer through radio frequency (RF) or direct cable communi­cation, depending on the model. The Model 2130 analyzer processes the data and
calculates the required machine moves necessary to bring the machine compo­nents into alignment.

With most alignment systems available today, the sag of the alignment fixtures must
be considered to accurately calculate machine moves. With the use of laser beams,
there is no fixture sag to consider! The RF communication between the sensor
heads and the Model 2130 analyzer simplifies data acquisition and reduces oper­ator error. The direct cable connect provides an alternate method to transfer data
when the RF link is not practical.

Since each head has a self-contained inclinometer and additional memory, the
data can be acquired through a variety of methods. Choices range from the tradi­tional top, bottom, left, and right locations (minimum of three) - where the fixtures
interact directly with the analyzer to the patented partial sweep method (the sensor
heads memorize the data and later dump it to the analyzer).

When the 8215/8225 fixtures and the 2130 Laser Align program are used with the
UltraMgr PC software program, a complete alignment program can be managed
from a centralized location. UltraMgr provides job tracking, control of alignment
tolerances, alignment history and much more.

1-3How To Use This Manual

Some advantages of the UltraSpec Pro 8215/8225 Laser Alignment Fixtures are:

•Easy setup

•No fixture sag

• Visible laser to assist with rough alignments

• Large diameter mounting range

• Large span range between sensor heads

• Large vertical expansion to clear larger couplings

• Large misalignment measurement range

• Partial revolutions (down to 45°)

• Dual Pass method for uncoupled alignments

• Real time machine move monitoring, vertical and horizontal

• Soft foot locator

• Radio frequency communication

• Direct cable connect, if needed

• Automatic data acquisition

•Dual beam technology

1-4

• Internal angle sensors

• Internal memory

• 45-minute charge cycle for sensor heads

• Simultaneously charging, sensor heads and analyzer

• Best ambient light protection

• Vertical machine alignment

• Straightness measurement

Emphasis Paragraphs

Note

Caution!

Warning!

Two different types of paragraphs are used throughout this manual to call attention
to the adjacent text:

The note paragraph indicates special comments or instructions.

The caution paragraph alerts you to actions that may have a major impact,
such as lost data or damage to the analyzer or its accessories.

The warning paragraph warns you of actions that could cause serious
personal injury or death.

Analyzer Serialization

The loaded firmware has been serialized and is matched to the analyzer serial
number. If the firmware and analyzer serial numbers do not match, contact
Product Support.

1-5How To Use This Manual

UltraMgr Software and Prerequisites

Note

Your AMS™ Suite: Machinery Health™ Manager software and
Model 2130 RBMC

Requirements

ONSULTANT PRO must have compatible software.

Model 2130 RBMCONSULTANT PRO firmware version v.6.3.8.0 or later.

The following, 4.90 or later, AMS™ Suite: Machinery Health™ Manager files ­dated 08/08/2005 or later:

•RBMcom.exe

•RBMcomSr.exe

•XFrAlg.dll

•UltraAlg.exe

UltraMgr requires some planning and setup before jobs can be down-loaded into
this alignment program. Refer to the appropriate UltraMgr user’s manual for more
information on communicating with the PC.

1-6

Standard Equipment

Note

When checking the kit to ensure that everything ordered was shipped, compare
the contents of the package to your shipping invoice. For additional assistance,
refer to the following fixtures case layouts. If a discrepancy is found, call Emerson
Customer Support at [phone].

Fixtures Case Layout (bottom section)

Some parts shown in these illustrations may be optional in different
packages.

1-7Standard Equipment

Fixtures Case Layout (top section)

1-8

Chapter

Warning!

Warning!

Warning!

Setting Up and Using Laser Alignment Fixtures

Special Instructions About the 8215/8225 Laser Fixtures

Prior to mounting the laser alignment fixtures on machine shafts, all
switches operating the machines should be “locked out” (follow
lockout procedures for your facility). On completion of the align­ment, inspect the work area to ensure that all equipment is clear of
rotating shafts and couplings, prior to removal of the lockout protec­tion.

2

The 8215/8225 Laser Alignment Fixtures use a Class II (CDRH) laser
or Class 2 (IEC) laser. This laser complies with 21 CFR 1040.10 and

1040.11 safety requirements with a power output < 1.0 mW (average)
and a pulse repetition of 600 pulses/sec. The pulse duration is <110
microseconds. However, do not expose the human eye directly to the
laser beam! Warnings are located on each sensor head.

Using the controls or adjustments in ways other than specified in this
documentation may result in hazardous laser radiation exposure.
Making the hardware, firmware, or software perform in ways other
than specified in this documentation may result in hazardous laser
radiation exposure.

2-1

Laser heads, front view

Laser heads, rear view

2-2 Setting Up and Using Laser Alignment Fixtures

Note

Only the Models 821501 and 822501 direct-connect only laser sys­tems have CE approval.

Laser radiation caution

2-3

Models 821500 and 822500 RF Laser Systems Only

Note

Note

Caution!

Caution!

Operation is subject to the following two conditions: (1) this device
may not cause interference, and (2) this device must accept any inter­ference, including interference that may cause undesired operation
of this device.

This equipment has been tested and found to comply with the limits
for a Class A digital device, pursuant to Part 15 of the FCC Rules.
These limits are designed to provide a reasonable protection against
harmful interference when the equipment is operated in a commer­cial environment. This equipment generates, uses, and can radiate
radio frequency energy and, if not installed and used in accordance
with the instruction manual, may cause harmful interference to radio
communications. Operation of this equipment in a residential area is
likely to cause harmful interference in which case the user will be
required to correct the interference at his own expense.

Changes or modifications not expressly approved by Emerson could void the
user's authority to operate the equipment.

This device has been designed to operate solely with the antenna type provided,
Emerson part number 88200. An antenna having a higher gain is strictly pro­hibited per regulations of Industry Canada.

2-4 Setting Up and Using Laser Alignment Fixtures

General Description

Note

RF Antenna

RF Antenna
Housing

Direct
Connect
Port

Targ et s

(PSD’s)

Sensor
Head ID

Laser
Source

Charging
Port

Horizontal
Laser
Adjustment

Vert ical
Laser
Adjustment

Power

Button

Post
Grip

Activity
LED

Laser Head
Model #

Sensor Head Description

This section describes both the old and current versions of the 8215/8225 laser
heads. The older version of heads can be identified by their gray front panels and
black grid lines. The current version of heads have different color front panels.
Head A has a gray front panel with white grid lines and blue on/off buttons, while
head B has a blue front panel with white grid lines and gray on/off buttons.

Throughout the manual, photos may contain images of either the
older or current versions of laser heads.

1

2-5General Description

The sensor head with the laser source on top is the Master head (known as head
“A”). The other head is the Slave (known as head “B”). The model number is listed
on the back of each head. They can be identified by the letter A or B on the front.

There are no differences between the older and current versions of the 8215/8225
laser heads with the exception of the front panels and batteries. The older version
is powered by nickel cadmium (NiCad) batteries, while the current version is pow­ered by Nickel Metal Hydride (NiMH) batteries.

The difference between the Model 8215 sensor heads and the 8225 sensor heads
are the target (Position Sensing Detector or PSD) size, laser distance, and the front
overlay. The 8215 sensor head has a 10mm x 10mm PSD and a laser which allows
alignments over a sensor spacing up to 30 feet, or 9 meters. The 8225 sensor head
has a 20mm x 20mm PSD and a laser which allows alignments over a sensor spacing
up to 100 feet (30.5 meters).

Although the direct-connect only laser system (Model 821501 and 822501) is not
illustrated in this manual, the only difference between it and the RF laser system
(Models 821500 and 822500) is that the RF system transmits information using
either the RF or direct-connect communication. The direct-connect only laser
system uses only the direct-connect communication. For this reason, the direct-con­nect only laser systems do not have an RF antenna or antenna housing.

2-6 Setting Up and Using Laser Alignment Fixtures

The Activity LED on the front panel can be red, yellow, or green. An explanation
of their meaning is shown in the following table.

LED Status Meaning Required Action

Green Yellow Red

X

Table 1:

Normal Operation - When the
Laser Head systems are all
functioning properly and the
laser beam from the companion
Laser Head is striking the PSD in
the linear region. This is the
desired state. The Laser Head is
in the acceptable condition to
perform an alignment.

No Action Required

X (flashing)

Sensor head in standby (sleep)
mode - When the Laser Head
sees no activity for five minutes,
they automatically enter Sleep
Mode to conserve battery
power. The color will be the
one that was active, solid or
flashing, before this state was
entered. When this sleep mode
is entered, the LED will be
flashed off for 1.5 sec. and on
for 0.5 sec.

Minor Error* Refer to “(6) Laser Head Status

X

Use analyzer to wake up when
needed by initiating
communication with the laser
heads.

Screen” on page 3-16 for more
information on the error and the
required action.

2-7General Description

LED Status Meaning Required Action

Green Yellow Red

X (flashing)

X

Table 1:

Low battery 1st warning (sensor
head) - The Laser Head has the
ability to monitor its own
battery power. The battery
power is checked periodically
to determine if it is below the
minimum acceptable power.
When the battery power
reaches 4.8 volts, the LED will
be flashed off for 0.5 sec. and
then flashed on for 0.5 sec. Data
is accepted when the battery is
this state.

Major Error* Refer to “(6) Laser Head Status

Recharge sensor heads.

Screen” on page 3-16 for more
information on the error and the
required action.

Recharge sensor heads.

X (flashing)

Low battery 2nd/final warning
(sensor head) - The Laser Head
has the ability to monitor its
own battery power. The battery
power is checked periodically
to determine if it is below the
minimum acceptable power.
When the battery power
reaches 4.2 volts, the LED will
be flashed off for 0.5 sec. and
then flashed on for 0.5 sec. Data
is not accepted when the battery
is this state.

* If a minor error is present, the data being acquired may be marginal. The data
quality will depend on the error. If a major error is present, then some kind of hard­ware or system problem exists. Therefore, the data being acquired is rejected.

2-8 Setting Up and Using Laser Alignment Fixtures

LED Functionality Difference Due to Dual Pass mode

Note

The functionality of the LED differs slightly from the states described in the above
table when the Dual Pass mode of operation is selected. The difference lies in the
LED state when the companion Laser Heads laser beam is on the PSD. In Dual Pass
mode, when the laser beam is on or off of the PSD the LED will be a solid yellow,
even when the beam is in the linear portion of the PSD. The beam will then flash
to green whenever a valid data point is acquired. This deviation is necessary to allow
for the indication to the user that the Laser Heads are acquiring data as they are
rotated past each other.

To determine the actual error, select the Check Lasers option on the
Alt screen. This will activate the Laser Heads Status screen. If an error
condition actually exists, its type will be shown in a popup window
within 60 seconds. Refer to the Check Lasers section for more infor­mation.

2-9General Description

General Maintenance

Caution!

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.

• Keep all lens free of grease, dirt, oil, and other smudges.

• Clean the laser and target lens with a soft, lint-free cloth and standard lens
cleaning solution (a field size cleaner container is available from Emerson).
Never use an organic solvent such as a thinner or benzine.

• Store sensor heads in protective hard-shell carrying case when not in use.

Calibration

The Model 8215/8225 calibration should be checked every two years. Return the
sensor heads to Emerson for a calibration check. All calibrations are NIST trace­able.

Do not remove the CSI Quality label on the back of the sensor head. This will
void your warranty.

2-10 Setting Up and Using Laser Alignment Fixtures

Battery Charging

Batteries must be charged with the Model 8211charger. The Model 8211 charger
is a “smart, drop-in” charger that can provide a fast- or trickle-charge for the laser
heads and analyzer.

This section describes both the old and current version of the 8211 charger. The
older version of the 8211 charger can be identified by its solid gray front panel. The
current version of the 8211 charger also uses a gray motif on the front panels, but
the area around the Fast and Discharge buttons is blue.

Model 8211 Smart Charger

The Model 8211 charger 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 analyzer being charged.

Charging the Sensor Heads and Analyzer with Model 8211 Charger.

2-11General Maintenance

The current version of the 8211 charger will charge both the former and current
versions of the 8215/8225 laser heads but at a slower charge rate than the older ver­sion of the 8211 charger. The former version of the 8211 charger charges the
former version of the 8215/8225 laser heads, but it will only trickle charge the cur­rent version of the 8215/8225 laser heads. Although no damage will occur if the
Fast Charge cycle is initiated, this cycle will not work for the current version of the
laser heads.

To set up the 8211 charger, complete these steps:

1. . . plug the power cord into the power supply,

2. . . plug the power cord into an AC receptacle,

3. . . plug the power supply into the 8211 charger in the top end cap.

At that time, the beeper will sound indicating that power has been applied to the
battery charger. As a test, all LEDs will illuminate for 1.5 seconds.

4. . . Plug the analyzer charging cable into the bottom end cap.

The sensor heads and analyzer can now be charged either individually or, all at the
same time.

Charging the Sensor Heads with the Model 8211 Charger

Drop them over the posts so that the head faces outward as shown in the previous
illustration. Heads can be charged individually or together.

Indicator Light Charging Status

Pending Waiting for safe voltage and

temperature

Discharge (steady) Batteries discharging

Discharge (flashing) Discharge requested, waiting

for safe voltage or temperature

Fast (steady) Batteries in fast charge

Fast (flashing) Fast charge requested, waiting

for safe voltage or temperature

Trickle Batteries in trickle charge,

topping-off, or charge complete

2-12 Setting Up and Using Laser Alignment Fixtures

Note

The discharge cycle is intended for older versions of the laser heads,

Caution!

powered by Nickel Cadmium (NiCad) batteries. This function is not
required for the current version of the laser heads, powered by Nickel
Metal Hydride (NiMH) batteries. However, use of this function on
laser heads with NiMH batteries will not result in any damage to the
heads or charger.

For maximum safety, the battery charger has a Pending status LED, which lights
momentarily when the head is first placed on the charger. If a battery is very low, or
is out of a specific temperature range, it cannot be safely charged. When this con­dition occurs the Pending indicator remains illuminated. While Pending, the
charger is actually charging the batteries at a very low rate in an attempt to charge
the low battery to an acceptable voltage range. Once the battery temperature and
voltage are suitable for charging, the charger automatically begins trickle charging
and the Trickle indicator light turns on.

To fast charge or discharge the battery the Fast button or Discharge button must
be pressed. If the Fast button or Discharge button is pressed while the battery
voltage is too low or temperature is not suitable for Fast or Discharge operation, the
indicator light will flash on and off. This response acknowledges the request but
indicates that the charger cannot fulfill the request at that time. Once voltage and
temperature conditions are suitable, the requested Fast or Discharge operation will
begin and the indicator light will change to a steady light.

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.

2-13General Maintenance

After the Fast charging cycle has completed, the charger’s beeper sounds and the

Note

charger automatically begins trickle charging. When this condition begins, the
Trickle indicator light turns on indicating that the battery is almost completely
charged, or is completely charged. For the laser head batteries, the two conditions
occur within a few minutes of each other. Charge time from a fully discharged set
of batteries to approximately a 90% voltage charge is 45 minutes (current version
of the 8211 charger) and 15 minutes for the former version of the 8211 Charger.

If the Discharge cycle has been initiated, on completion the charger automatically
begins fast charging and the Fast indicator light turns on. If charging a former ver­sion of the laser heads that contain NiCad batteries - to avoid the battery memory
concern use the Discharge mode when you have more than 20 minutes to charge
the sensor head batteries. The typical charge cycle is as follows:

Action Time

Press DISCHARGE button Start

DISCHARGE complete, FAST starts 7 minutes

FAST complete, TRICKLE starts – charging complete 22 minutes

NOTE: The heads can be left on TRICKLE indefinitely (until the next time they are
needed).

After power has been applied to the charger and the sensor head(s)
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
to charge the batteries. No LED's lit indicates a “no battery present”
state. If this takes place, remove the sensor head from the charger and
try reseating it back into the charger.

2-14 Setting Up and Using Laser Alignment Fixtures

Note

After a charging cycle begins, if that charging cycle is interrupted (e.g.
disconnecting the power to the charger or removing the sensor head
from the charger) the charging process described above initiates
from the beginning. Therefore, if the charger cycle is interrupted
while the Fast charge mode is in progress, then the charger automat­ically begins trickle charging after Pending(see below).

The “Pending LED” lights momentarily and switches into Fast charge. Charge time
for a fully discharged set of batteries is 45 minutes (for the current version of the
8211 charger) and 15 minutes for the former version of the 8211 charger. The
beeper will sound when both heads are fully charged and the charger switches to
trickle.

Charging the Analyzer with the Model 8211 Charger

Charging functions for the 8117, 2120 and 2130 analyzers are identical for both the
former and current versions of the 8211 charger.

Plug the charging cable (A821102) from the bottom end cap on the 8211 charger
into the charger port on the top end cap of the analyzer. The battery pack will
recharge in three hours. After the battery pack has been fully charged, the battery
charger automatically switches to a trickle charge.

2-15General Maintenance

Battery Usage - Laser Heads

Note

Power is supplied to each sensor head via a rechargeable battery pack. A fully
charged battery pack provides five to six hours of continuous service while transmit­ting data. Longer operation is possible since typical alignments do not require con­tinuous communication with the analyzer. The battery is designed to have a long
life and is not intended to be replaced by the user. Replacement should be per­formed only at Emerson. Emerson recommends that the batteries be replaced
after 500 charges.

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 starts the
sensor heads again. All data in memory is lost, therefore another sweep should be
taken.

The sleep and auto-shutdown modes can be disabled. To disable the sleep mode
on each laser head, with the laser heads off, press and hold the Power Buttons. This
will cause the laser heads and their corresponding LED’s to power on for approxi­mately two seconds. Then laser heads and their corresponding LED’s will power off
for approximately three seconds. After the laser heads and their corresponding
LED’s power back on again, the shutdown mode will be disabled. To re-enable the
sleep mode, just power the heads off.

Please note that this disables the battery conservation (for the sensor
heads) therefore, if the heads are left on, the batteries will run down.

2-16 Setting Up and Using Laser Alignment Fixtures

Precautions

Please follow these precautions carefully. Any product damage due to these condi­tions may void the warranty.

• Use only Emerson-supplied battery chargers that have been approved for

• Do not use Emerson battery chargers with anything other than the product

• Do not use any batteries other than those included and/or specified for the

• Do not connect a printer directly to the RS232 port located on the top panel

• Do not connect any adapters or accessories to the RS232 port located on the

• Do not start the machines being aligned with the laser alignment system

use with the analyzer and Model 8215/8225 laser heads. The use of any
other charger will most likely damage the equipment.

for which they are designed. Do not use the 8211 charger to charge any­thing else!

analyzer and 8215/8225 laser heads.

of the analyzer.

top panel of the analyzer while the analyzer is turned on.

equipment attached. Be sure to remove the laser system before starting the
machinery.

2-17Precautions

Introduction to Laser Alignment Fixtures Setup

Warning!

Warning!

This section takes you through a step-by-step setup of the 8215/8225 Laser Align­ment Fixtures. Before before beginning the actual machine alignment, be sure all
pre-alignment checks have been completed.

Prior to mounting the laser alignment fixtures on machine shafts, all
switches operating the machines should be locked out. Follow safety
precautions for your facility. Normally, only personnel performing
the alignment should be able to unlock any startup switch. After an
alignment has been completed, the work area should be inspected to
ensure that all equipment is clear of rotating shafts/couplings prior
to removal of the lockout protection.

The 8215/8225 Laser Alignment Fixtures use a Class II (CDRH) laser
or Class 2 (IEC) laser. This laser complies with 21 CFR 1040.10 and

1040.11 safety requirements with a power output < 1.0 mW (average)
and a pulse repetition of 600 pulses/sec. The pulse duration is <110
microseconds. However, do not expose the human eye directly to the
laser beam! Warnings are located on each sensor head.

Water vapor or dust can interfere with a target “seeing” its laser. The air between the
sensor heads should be visually clear. Ensure that the air between the sensor 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 laser fixtures at ambient temperatures. If the fixtures have been stored
at a different temperature than ambient, allow the laser fixtures to acclimate to
ambient. Ensure that any heat source that may be present is not creating a large
temperature difference between the laser fixtures and the ambient temperature.
Sunlight itself will not cause a laser reading problem.

2-18 Setting Up and Using Laser Alignment Fixtures

Attaching the Fixtures

Standard Nut Knurled Knob

This section shows how to attach and secure the mounting base, chains, align the
two mounting bases by leveling, install the sensor heads, turn on the sensor heads,
and center the lasers on their targets.

Attaching the B821007 Carbon Steel Mounting Base

The B821007 3/4 inch (19mm) wide carbon steel mounting bracket is suitable for
the majority of alignment jobs where the laser fixtures can be rigidly mounted to a
shaft that can be rotated freely.

Select the chain tightener of choice. The right photograph shows a knurled nut
which can be tightened by hand. The hex nut mechanism provides a more stable,
versatile mounting while the knurled nut is more convenient. Use each nut as
shown.

2

These photographs illustrate how the chain assembly should be slipped into the
mounting base. Hold the chain out away from the base and slip the cylinder into its
cradle. To ensure maximum tightening range, each nut should be flush with the
end of the tightening bolt.

2-19Attaching the Fixtures

Attaching Chain to the Chain Pickup

This photograph illustrates how the chain attaches and actually clamps the shaft.
The base is placed on the shaft (or coupling) and a link of the chain is slipped into
the chain pickup to secure the base to the shaft. After slipping a chain link into the
chain pickup, tighten the bolt at the end of the chain.

2-20 Setting Up and Using Laser Alignment Fixtures

Allowing Maximum Tightening Range

To allow for maximum tightening range, ensure that the chain nut is flush with the
end of the chain bolt (as shown by arrow). Notice that the chain bolts are on oppo­site sides. As shown in later sections, each mounting base can be installed on either
end and the chain bolts placed on either side of the shaft.

2-21Attaching the Fixtures

Positioning a Mounting Base

Caution!

Tighten one of the mounting bases and rotate it (along with the shaft) until it is
somewhat level at the top of the rotation. To tighten the mounting base, use a 9/16 inch

wrench or your hand, depending on which chain tightener is being used.

Do not overtighten the chain — the maximum tightening torque is 10 ft.-lbs.

2-22 Setting Up and Using Laser Alignment Fixtures

Positioning the Other Mounting Base

With the previous mounting base still in its level position, if necessary, loosen and
rotate the other mounting base until it is somewhat level with it. Tighten this base
and recheck the other base to ensure that both are now level in relation to one
another.

Although this part of the procedure is not absolutely critical, placing the mounting
bases relatively level with each other allows the laser beam adjustment to be more
or less centered. This ensures that the laser beams can line up with their targets
easily.

Also, there may be times when the top position is not accessible. The objective of
this step is to mount the sensor heads in the same rotational position. This provides
the maximum rotational range for the sensor during data acquisition.

2-23Attaching the Fixtures

Attaching Excess Chain

One of the problems with using chains as a mounting bracket is that the excess
chain flops and can cause errors. CSI’s Laser Alignment Fixtures provide solutions
for this problem.

Two slots are provided (one on either side) to take up the slack. As shown in the
following photographs, you can use either or both of the slots as needed. The order
of use is not important. In fact, the L-slot cannot be used when mounting to shafts
(or couplings) greater than 3 inches (76 mm) in diameter. When fastening the
chain into the T-shaped slot, the rubber block will hold the chain in place.

The photograph below illustrates using the T-shaped slot; see the following page for
an example using the L-shaped slot.

Using the T-shaped Slot

2-24 Setting Up and Using Laser Alignment Fixtures

Caution!

Using the L-shaped Slot

Do not attach excess chain prior to tightening the mounting base chain bolts.
Doing so may cause damage to the L and T-shaped slots.

2-25Attaching the Fixtures

Using the Chain Clip

You will almost always have a little extra chain left over. In that case, use the chain
clip (part number D22745) to attach it to the previous chain loop. Emerson recom­mends that you use this clip to help prevent the chain from sliding out of the
L-slot as the shafts are rotated.

2-26 Setting Up and Using Laser Alignment Fixtures

Installing a Post

Screw a mounting post (part number D23465) into each of the outer holes in the
mounting base. Tighten each post with the supplied tightener (Phillips screw­driver) or with a 1/8 inch Allen wrench (not supplied with kit).

2-27Attaching the Fixtures

Mounting a Sensor Head

Note

The gray sensor head with the laser source on top is designated head
“A”. The “B” designation is attached to the blue sensor head with the
laser source on the bottom. In addition to their color difference,
head A and B are identified with letters on the front panel.

Place a sensor head on the two posts. It does not matter on which side Head A or
Head B is mounted — the heads will be configured in the analyzer. Adjust to desired
position and tighten each post clamp finger tight. The mounting posts allow up to

1.5 inches (38 mm) of vertical adjustment. If more vertical adjustment is needed,
use the vertical extension blocks. See “Introduction to Special Applications” on
page 2-46 through “Adding a 2-inch (51 mm) Block” on page 2-48 for additional
information.

2-28 Setting Up and Using Laser Alignment Fixtures

Note

Longer mounting posts are not available. However, if you wish to
make your own, refer to the mechanical drawing of a mounting post
in the section entitled “Mounting Post (part number D23465) For
Alignment Brackets” in Appendix B.

2-29Attaching the Fixtures

Models 821500 and 822500 RF Laser Systems Only

Depending on the clearance around which the laser head will be rotated, the posi­tion of the RF antenna may have to be adjusted. When the antenna is in its most
upright position it extends up above the top of the laser head. Holding the antenna
housing (not the antenna itself), rotate or twist the antenna down (or up
depending on its starting position) to its desired position. The antenna’s rotational
arc is 30 degrees. When the antenna is in the down position it does not extend
above the top of the laser head.

3

2-30 Setting Up and Using Laser Alignment Fixtures

Mounting the Other Sensor Head

Install the opposite sensor head in the same manner (Head A or Head B,
depending on which sensor head was mounted on the other side).

2-31Models 821500 and 822500 RF Laser Systems Only

Communication Between the Fixtures and Analyzer

Note

Caution!

The analyzer conducts communication with the fixtures via a short-range, low­power radio frequency (RF) carrier (916.5 MHz) or by cable.

Radio Frequency (Models 821500 and 822500 only) - With RF, communication
occurs in much the same manner as with other short-range wireless systems (for
example, cordless phones) — a direct line-of-sight communication is not required.

A typical operating range of up to 50 feet (15 meters) can be achieved using RF
communication, but this range is greatly influenced by building construction mate­rials and contents, other radio systems operating in the vicinity at or near the same
operating frequency, and noise generated by nearby equipment. It is not unusual
to achieve four times the typical operating range in electrically quiet environment
or to achieve less than the typical operating range in an electrically noisy environ­ment.

This equipment has been tested and found to comply with the limits
for a Class A digital device, pursuant to Part 15 of the FCC Rules.
These limits are designed to provide a reasonable protection against
harmful interference when the equipment is operated in a commer­cial environment. This equipment generates, uses, and can radiate
radio frequency energy and, if not installed and used in accordance
with the instruction manual, may cause harmful interference to radio
communications. Operation of this equipment in a residential area is
likely to cause harmful interference in which case the user will be
required to correct the interference at his own expense.

Changes or modifications not expressly approved by Emerson could void the
user's authority to operate the equipment.

There may be times when an RF communication between each sensor head and
the analyzer is not convenient. Moving or keeping the analyzer closer to the laser
heads can minimize this inconvenience.

2-32 Setting Up and Using Laser Alignment Fixtures

The sensor heads have memory for saving alignment readings. If communication
with the analyzer is broken during rotation (while using the Auto Sweep mode),
these readings are stored in memory until they can be transmitted. When the
sensor head is turned off, the memory data is erased.

If the analyzer is out of range of one or both sensor heads or if some sort of RF inter­ference is occurring, it will repeatedly attempt to communicate with the sensor
heads. A message will be displayed on the analyzer until the communication link is
established.

When communication using RF becomes difficult, Emerson recommends that you
use the Direct Connect link as described in “Direct Connect (All Models)” on page
2-36.

2-33Models 821500 and 822500 RF Laser Systems Only

Connecting the 8000RF Interface

Attaching 8000RF to 25-pin Connector

Install the 8000RF Interface onto the serial port of the analyzer by completing the
following steps:

1. . . Ensure that the Model 2130 analyzer is turned off.

2. . . Connect the 25-pin connector of the 8000RF Interface to the RS-232 port on
the Model 2130 analyzer.

3. . . Turn the Model 2130 analyzer on.

2-34 Setting Up and Using Laser Alignment Fixtures

Caution!

Do not rotate or twist the antenna on the 8000RF Interface. Attempting to do so
will damage the unit.

The Attached 8000RF Interface.

2-35Models 821500 and 822500 RF Laser Systems Only

Direct Connect (All Models)

Note

Direct Connect is designed for those conditions where it is difficult to communi­cate between the analyzer and the sensor heads using RF. Conditions such as
building construction materials and contents, other radio systems operating in the
vicinity at or near the same operation frequency, and noise generated by nearby
equipment all may make RF communication unsatisfactory.

Both the A800001 and A821510 Direct Connect cables will work with
the 8215/8225 laser heads for all modes of operation where commu­nication between the laser heads and analyzer are necessary, except
for the Dual Pass mode. Only the A821510 cable can be used for the
Dual Pass mode when using direct-connect communication.

2-36 Setting Up and Using Laser Alignment Fixtures

To use Direct Connect, complete these steps:

Note

Note

1. . . Make sure the analyzer is turned off.

2. . . Attach the 25-pin connector of the direct connect cable to the RS232 port on
top of the analyzer.

3. . . Connect the Lemo connectors of the direct connect cable to the mating
straight Lemo connector on the extension cables, if applicable.

When connecting the Lemo connector to its mating connector, line
up the red dots located on each connector with each other before
completing the connections. To complete the connection, push the
connectors together. Do not twist.

4. . . Connect the Lemo connector on the opposite end of the cable to the Lemo
port under the nose of each 8215/8225.

When connecting the Lemo connector to its mating connector, line
up the red dots located on each connector with each other before
completing the connections. To complete the connection, push the
connectors together. Do not twist.

5. . . Turn the analyzer on.

From this point on, Direct Connect is very easy to use. The analyzer determines that
it is connected and disables the RF communication (Models 821500 and 822500
only). Cables can be unplugged and reconnected at any time (and at any connec­tion). You do not have to remember which cable is plugged to which head. Even if
you switch the orientation of the cables (when reconnecting), the analyzer can
adjust to the change and will still work correctly.

2-37Models 821500 and 822500 RF Laser Systems Only

Caution!

When using any cable connector inside the sensor head connector, do not turn
or twist the connector. This will shear the cable pins off (inside the connector)
totally disabling the sensor head and cable. Pull the cable connector completely
out of the sensor head connector before turning the cable.

The direct connect cable is 5 feet (1.5 m) long with “pigtail” style cable. When
standing between the sensor heads, a 6 feet (1.8 m) span can be aligned,
depending on the diameter of the shaft. Extension cables, Model 800002 and
Model 800003, are available for longer spans, larger diameter shafts, or if you
cannot stand directly in the middle.

4

2-38 Setting Up and Using Laser Alignment Fixtures

The extension cables are eight feet (2.4 meters) long. With two extension cables

Note

and the connection pigtail, the total length is 13 feet (4 meters). When standing
between the sensor heads, a 22 foot (6.7 meters) span can be aligned, depending
on the diameter of the shaft.

5

With the 8215, a maximum distance of 30 feet (9 m) between the
laser heads can be achieved. With the 8225, a maximum distance of
100 feet (30.5 m) between laser heads can be achieved.

2-39Models 821500 and 822500 RF Laser Systems Only

Turn the Laser Beams On

Warning!

To turn the laser beams on, press the power button on each sensor head. See “Bat­tery Usage - Laser Heads” on page 2-16 for power button options.

Although the laser in the 8215/8225 system is low in intensity (< 1.0
mW), never direct the beam at a human eye. Use of controls, or
adjustments, or performance of procedures other than those speci­fied by Emerson may result in hazardous laser radiation exposure. To
do so could result in serious personal injury. Always ensure that the
sensor heads are mounted securely before turning on the laser beam.

2-40 Setting Up and Using Laser Alignment Fixtures

Center the Laser Beams

Vertical Adjustment Horizontal Adjustment

Center both Lasers on their associated target by adjusting the thumb wheels on the
front of each sensor head.

2-41Models 821500 and 822500 RF Laser Systems Only

Rough Alignment of the Laser Beams

1. Center laser beams
in respective targets

3. Estimate distance
moved by laser beam

Laser beam
position after
heads have
been rotated
180°

4. Move machine to position
beams approximately half distance
back toward center of target

2. Rotate laser
heads 180°

.

.

Rough alignment may be required to keep the laser beam on the target as the fix­tures are rotated. Either of these methods can be used:

Visible Beam Rough Alignment

This adjustment must be performed in each of the movement planes (typically
horizontal and vertical, when required). A horizontal adjustment is illustrated in
the following figure; duplicate the actions for vertical adjustments.

• Visible Beam rough alignment — utilizes the visible laser beams without the
use of the analyzer

• Partial Sweep rough alignment — utilizes the partial sweep capabilities of the
analyzer

Rough Horizontal Laser Beam Adjustments

2-42 Setting Up and Using Laser Alignment Fixtures

The gridlines on the front panel should assist you in determining the approximate
movement(s) needed to rough the machines in. Gridline spacing is 0.3 inches (7.5
mm). The following table shows recommended moves based upon the gross move­ment of the laser beam on the sensor head. Gross movements are discussed in ver­tical terms for simplicity.

6

2-43Models 821500 and 822500 RF Laser Systems Only

Note

Gross Movement

at Gearbox at Motor

Recommended Machine Move

Small Large,

down

Large,
down

Large, up Large,

Large,
down

Large, up Large, up Angular – add shims under the outboard feet of both

Large down Large down Angular – remove shims from the outboard feet of both

Small Angular & Offset – add shims under the inboard Motor

down

Large, up Offset – add shims to all feet of the Motor or remove

Angular & Offset – add shims under the inboard
Gearbox feet or remove shims from the outboard
Gearbox feet.

feet or remove shims from the outboard Motor feet.

Offset – add shims to all feet of the Gearbox or remove
shims from all feet of the Motor.

shims from all feet of the Gearbox.

machines or remove shims from the inboard feet of both
machines.

machines or add shims under the inboard feet of both
machines.

There will, of course, be combinations of the movements shown in
the previous table. However, these recommendations should provide
some general guidelines.

Partial Sweep Rough Alignment

In this method, you must use the fixtures and set the analyzer to Manual Sweep or
Auto Sweep mode. Either method can provide an effective target area much larger
than the 20 mm x 20 mm surface area. If the fixtures can be rotated and both
beams remain on target greater than 90° (recommended) of the sweep, the analyzer
can produce an alignment solution from the data taken. Data gathered from the
portion of the sweep that the laser beams were off target is rejected. For more infor­mation about sweep data collection modes, see Chapter 6.

2-44 Setting Up and Using Laser Alignment Fixtures

This procedure also works when using the Dual Pass mode.

Note

Roughing in the machine so that the laser beam is kept on the target
(PSD) as the laser fixtures are rotated can be quicker with a larger
PSD (e.g. with the 20x20mm PSD on the 8225 laser fixtures).

2-45Models 821500 and 822500 RF Laser Systems Only

Introduction to Special Applications

This section covers using additional mounting blocks, mounting on large diame­ters ( shafts > 8 inches (203 mm), and using alternative mounting brackets. Nor­mally, additional blocks are used to achieve greater coupling clearance. In some
cases, you may find that one (or both) of the mounting blocks must be installed on
the coupling itself. For larger diameter shafts (or mounting on a coupling), addi­tional lengths of chain may also be needed to mount the base.

2-46 Setting Up and Using Laser Alignment Fixtures

Using Additional Mounting Blocks

Note

Additional 1-inch, 2-inch, and 4-inch (25 mm, 51 mm, and 102 mm) mounting
blocks are available for greater coupling clearances when using the B821007
carbon steel mounting bracket and the A800052 soft-mount (non-rotational)
mounting bracket.

Mounting a One-inch (25 mm) Block

This photograph shows a 1-inch (25 mm) block being mounted onto the
mounting block itself.

Emerson recommends that you tighten all vertical mounting block
cap screws to 50 in-lbs (without lubrication).

2-47Using Additional Mounting Blocks

Adding a 2-inch (51 mm) Block

This is a picture of a 2-inch (51 mm) block being attached on top of the 1-inch (25
mm) block (the blocks can be stacked in either order).

2-48 Setting Up and Using Laser Alignment Fixtures

7

This shows the complete 3-inch (76 mm) extension setup. The following table lists
which blocks are to be used for the various vertical extension ranges.

For Vertical Extension

Length (inches)

Use These Block(s)

(inches)

00

11

22

31, 2

2-49Using Additional Mounting Blocks

Mounting One Bracket on a Coupling

If at all possible, Emerson recommends that you mount the brackets on the shafts.
However, this is not always possible. Occasionally, you may have to mount the
bracket on a coupling.

This view shows the B821007 carbon steel mounting brackets being mounted to
the shaft on one side and the coupling on the other. In order to do this, you may
have to use a vertical extension block(s). In the example shown above, a 1-inch (25
mm) extension block is being used on the right side; no block is used on the left
(coupling) side.

2-50 Setting Up and Using Laser Alignment Fixtures

Mounting on Shafts (or Couplings) > 8-inch (203 mm) Diameter

Although the mounting base itself can be used on shaft diameters up to 26 inches
(660 mm), additional section(s) of chain must be used for applications greater
than 8 inches (203 mm) in diameter. Emerson sells extension lengths in two-feet
chain increments for the B821007 carbon steel mounting bracket (part number
D22773) and the A800052 soft-mount (non-rotational) mounting bracket (part
number A832001). In addition to the chain itself, extension kits include a clevis pin
and a hair pin, which are used to connect the sections of chain together.

Refer to the following table to determine chains needed with various shaft diame­ters.

For Shaft Diameters Inches

(mm)

Less than 8 (203) Standard Chain Length

1

8 - 15
(203 – 394)

15
(394 – 584)

23 – 26
(584 – 660)

1

/2 – 23

/

2

Use These Chain Lengths

Standard Chain Length +
1 Optional Length

Standard Chain Length +
2 Optional Lengths

Standard Chain Length +
3 Optional Lengths

2-51Using Additional Mounting Blocks

Using Alternative Mounting Brackets

Attaching the A800052 Soft-Mount (Non-Rotational) Mounting Base

The A800052 soft mount bracket was developed for machines with shafts or rotors
that are too large and heavy or difficult to turn like cement kilns, rock crushers,
gearboxes and hammer mills. This bracket is typically used for uncoupled align­ments where either the Manual Sweep or Dual Pass methods are being used. It has
eight shielded ball bearings mounted at the base of the bracket so that the bracket
actually rolls around the shaft.

Nylon nuts that come in the package can be added to the chain to allow it to easily
slide over the shaft while providing a stable mounting configuration. If necessary,
install the nylon nuts through slots in the chain using the 6-32 x 1/2 inch panhead
screw (provided) so that they are evenly spaced.

8

2-52 Setting Up and Using Laser Alignment Fixtures

Before using, inspect the soft mount base to ensure that all eight ball bearings are

Caution!

Caution!

tight and free of play. Screw the mounting posts into each hole in the mounting
base and tighten with the supplied tightener (Phillips screwdriver) or with a 1/8
inch Allen wrench (not supplied with kit). Select the chain tightener of choice
(refer to “Attaching the B821007 Carbon Steel Mounting Base” on page 2-19 for
more information). The hex nut mechanism provides a more stable, versatile
mounting while the knurled nut is more convenient. The chain assembly should
be slipped into the mounting base so that the nylon nuts rest against the surface of
the shaft (or coupling). Hold the chain out away from the base and slip the cylinder
into its cradle. To ensure maximum tightening range, each nut should be flush
with the end of the tightening bolt.

Place the base on the shaft (or coupling); a link of chain is slipped into the T-slot to
secure the base to the shaft. The soft-mount base does not have a chain pickup like
the B821007 Carbon Steel Mounting Base. After slipping a chain link into the T­slot, tighten the bolt at the end of the chain. Each mounting base can be installed
on either end and the chain bolts placed on either side of the shaft. Take up any
slack in the chain using the chain clip (if necessary) and mount the laser fixtures to
the posts as described in the section “Attaching the B821007 Carbon Steel
Mounting Base” on page 2-19. The following photographs show the base mounted
to a shaft. Grasping the bracket (not the laser fixtures) rotate the soft-mount base
around the shaft (or coupling).

Grasping the laser fixtures could result in less accurate, unrepeatable data. This
is especially important when using the Dual Pass method where the data is auto­matically acquired as one fixture passes by the other.

Coupling run-out will severely affect the accuracy of the soft mount brackets.
Coupling run-out should be measured and subtracted from the reading during
use.

2-53Using Alternative Mounting Brackets

Caution!

To ensure measurement accuracy, the contact surfaces of the shaft (or coupling)
must be free of dirt, grease, oil, etc. If cleaning is needed, Emerson recommends
that you use a solvent-base cleaner. Shaft keys should be avoided to reduce errors
in accuracy.

9

2-54 Setting Up and Using Laser Alignment Fixtures

Attaching the A8AA54 Narrow Mounting Base

The A8AA54, 1/2 inch (13mm) wide, narrow bracket was developed for small
machines with shaft diameters of 4 - 1/2 inches (114 mm) and below, where the
shaft can be rotated freely. Top and bottom v-shaped bars clamp snugly around the
shaft. All is held in place by any one of three fasteners: wing nuts for easy tightening,
hexagonal nuts for easy tightening in close quarters or a 1/2 inch (13mm) cou­pling nut for especially tight spaces. The bolts are hinged and can swing freely. A
cotter pin can be inserted into the bracket to prevent the bolt from swinging.

10

Place the top v-shaped bar section (base) of the bracket on the shaft and the
bottom v-shaped bar section of the bracket on the shaft (on the opposite side of the
shaft from where the top v-shaped bar section has been placed) to secure the
bracket to the shaft. Ensure that the bolts are seated in the outer most slots of the
bottom section. When the top and bottom v-shaped bar bracket sections and bolts
are in place, tighten the nut at the end of the bolt to clamp the bracket to the shaft.

2-55Using Alternative Mounting Brackets

Screw the mounting posts into each hole in the mounting base and tighten with

Note

the supplied tightener (Phillips screwdriver) or with a 1/8 inch Allen wrench (not
supplied with kit). Mount the laser fixtures to the posts as described in “Attaching
the B821007 Carbon Steel Mounting Base” on page 2-19. The photograph shows
the base mounted to a shaft.

11

Extension blocks are not available for this bracket.

2-56 Setting Up and Using Laser Alignment Fixtures

Attaching the A8AA55 Quick Mount Narrow Mounting Base

The A8AA55, 1/2 inch (13mm) wide quick mount narrow bracket is a chain type
bracket for optimal stability in tight spaces on a wide range of shaft sizes, where the
shaft can be rotated freely. The chain assembly should be slipped into the
mounting base. Hold the chain out away from the base and slip the cylinder into its
cradle. To ensure maximum tightening range, each nut should be flush with the
end of the tightening bolt.

12

Place the base on the shaft (or coupling) and a link of chain is slipped onto the pin
located on the opposite side of the bracket to secure the base to the shaft. After slip­ping a chain link onto the pin, tighten the bolt at the end of the chain. The bracket
is held in place by a 1/2 inch (13mm) coupling nut for especially tight spaces. Each
mounting base can be installed on either end and the chain bolts placed on either
side of the shaft. Take up any slack in the chain using the hairpin chain clip (if nec­essary).

2-57Using Alternative Mounting Brackets

Screw the mounting posts into each hole in the mounting base and tighten with

Note

the supplied tightener (Phillips screwdriver) or with a 1/8 inch Allen wrench (not
supplied with kit). Mount the laser fixtures to the posts as described in “Attaching
the B821007 Carbon Steel Mounting Base” on page 2-19. Once the posts are in
place, mount the laser fixtures to the posts. The photograph shows the base
mounted to a shaft.

13

Extension chains and blocks are not available for this bracket.

2-58 Setting Up and Using Laser Alignment Fixtures

Attaching the A800056 Magnetic Mounting Base

The A800056 9/16 inches (14 mm) thick magnetic bracket was developed to
mount on the side of couplings made of ferromagnetic material. Recommended
minimum coupling diameter is 3-4 inches (75-100 mm), where the shaft can be
rotated freely. Each bracket consists of a light-weight delron housing containing
seven, powerful rare-earth magnets. The bracket lip overhangs the coupling rim to
provide extra stability. With this accessory it is possible to attach the alignment fix­tures within seconds of tagging out a machine for so-called "hot alignment" checks.

14

2-59Using Alternative Mounting Brackets

Screw the mounting posts into each hole in the mounting base and tighten with
the supplied tightener (Phillips screwdriver) or with a 1/8 inch Allen wrench (not
supplied with kit). Mount the laser fixtures to the posts as described in “Attaching
the B821007 Carbon Steel Mounting Base” on page 2-19. Attach the base to the
inside or outside of the coupling, depending on the coupling design and whether
or not you are performing a coupled or uncoupled alignment. The photograph
illustrates the base attached to the outside of a coupling.

15

2-60 Setting Up and Using Laser Alignment Fixtures

Horizontal Alignment

The horizontal alignment feature of the Advanced and Basic Laser Align applica­tions is used to collect and display alignment data for machines in which the
machine moves are accomplished at the machine feet.

Help

Depending on where you are within the program, an alignment helper may be
available at the bottom of the screen to provide you with a brief explanation of the
highlighted step or screen. In addition to the alignment helper, the functionality of
any soft key is available. This is accessed by pressing the 2130 analyzer Help key
once, and then pressing the soft key for which help is desired. Pressing the Help key
twice returns a help message for the active program screen. If further help is
required, refer to the appropriate section(s) in this manual.

Chapter

3

Basic Alignment Steps

Three basic steps are required to complete an alignment job.

1. Define the alignment job

• Setup the job parameters.

• Enter machine dimensions.

2. Acquire alignment data

• Acquire alignment data to determine the alignment condition of the
machine.

3. Review alignment results

• Review machine moves.

• Move the machine, if necessary.

3-1

Advanced and Basic Laser Align Applications

The laser alignment program is available as an advanced laser align program
(which includes the ability to perform Basic jobs), and as a basic laser align pro­gram (which can only perform basic alignment jobs).

Advanced Laser Align

If the Advanced Laser Align application is loaded in a 2130 analyzer, the program
can be launched from the 2130 analyzer’s Home screen by pressing the Adv Laser
Align soft key. When the advanced application is selected, you will have access to the
full functionality described throughout this manual. The ability to perform basic
laser align jobs is included in this program.

Basic Laser Align

If the Basic Laser Align application is loaded in a 2130 analyzer, the program can
be launched by pressing the Basic Laser Align soft key on the 2130 analyzer home
page. When the basic application is selected, you will have access to a subset of the
functionality described throughout this manual. Refer to the Basic Mode section
on page 3-12 for a detailed description of the functionality available in the Basic
Laser Align application.

3-2 Horizontal Alignment

Main Screen

Note

The main Laser Align Application screen (sometimes referred to as the Main
Menu) allows you to monitor progress throughout the alignment job. When a hor­izontal alignment job is active, the Main screen displays as illustrated below.

Laser Align Application Main screen at job start

The application defaults to a predefined setup when a new job is created. The type
of job, Job ID, Equipment ID, alignment method, number of machine moves, and
number of notes attached to the job are displayed in the upper portion of the main
screen.

Unless otherwise noted, any defaults listed are displayed only at first.
Once a field is modified from the default, the program uses the latest
entry for that field.

3-3Main Screen

The steps required to perform an alignment are displayed in the center portion of
the main screen. The 2130 Laser Align program leads you through each step of a
routine alignment procedure starting with the Enter Dimensions selection at the
Main screen. Once an alignment job has started the next uncompleted step in the
recommended procedure is highlighted.

An [X] signifies a completed step. As you complete steps, the next recommended
step is highlighted. Initially, the Move Machine step is displayed, but grayed out
until you’ve completed first two required steps which are critical to the alignment
jobs.

Up and Down Arrow keys

Use the Up and Down Arrow keys to highlight each feature. If you select an inactive
step, a popup message reminds you that the selected step is inactive due to missing
information.

3-4 Horizontal Alignment

Three Step Alignment

To simulate the basic steps required to complete a horizontal alignment job, the
2130 Laser Align main screen is set up to allow an alignment job to be performed
using the following three steps:

1. enter dimensions,

• enter machine dimensions

• if thermal growth is enabled, enter thermal growth information; otherwise,
this step is skipped

2. sweep laser heads,

• if foot pre-check is enabled, perform Soft Foot or FDI check; otherwise, this
step is skipped

• acquire alignment data to determine the alignment condition of the
machine

3. move machine

•review vertical moves

• review horizontal moves

• perform a live move (optional) and move the machine.

3-5Three Step Alignment

Main Screen Function Keys

Note

Enter Dimensions

Use the Enter Dimensions key to advance to the Edit Dimensions screen where the
dimensions for the machine being aligned can be entered. This is the first step of
the three-key operation used in performing an alignment job. If thermal growth is
enabled, thermal growth information can also be entered from under this step.
Refer to the Enter Dimensions section on page 3-45 for more information.

Sweep Laser Heads

Use the Sweep Laser Heads key to advance to the data acquisition screen for the
alignment method defined for the job. This is the second step of the three-key
operation used in performing an alignment job. From this screen alignment data
needed to determine the alignment condition of the machine is acquired. If foot
pre-check is enabled, a Soft Foot or FDI check can also be performed from under
this step. Refer to the Sweep Laser Heads section on page 3-75 for more informa­tion.

Move Machine

Use the Move Machine key to advance to the Vertical Move screen where the
machine moves and alignment condition for the vertical direction can be reviewed.
This is the third step of the three-key operation used in performing an alignment
job. After the Vertical Move screen, the program advances to the Horizontal Move
screen where the machine moves and alignment condition for the horizontal
direction can be reviewed. If an alignment correction is necessary that requires a
live move, this can also be done from under this step. Refer to the Move Machine
section on page 3-129 for more information.

The Enter key will perform the same function as the soft key for the
highlighted program step. In addition, the Enter key can be used to
advance you through an alignment job from beginning-to-end using
the job parameters and flow setup on the Alt Main screen.

3-6 Horizontal Alignment

Alt Main Screen

The Alt Main screen (also known as the Main Menu Alt2 screen) allows you to
setup alignment job parameters and job flow. The Alt Main screen is reached by
pressing the Alt key on the Main screen.

Laser Align Application Alt Main (Advanced Mode)

3-7Alt Main Screen

Alt Main Screen Function Keys

Notes

Use the Notes key to advance to the Notes screens where notes can be assigned to
the current job. In addition to the predefined notes, user defined notes can also be
created and assigned to the current job from under this option. Refer to the Notes
section on page 3-180 for more information.

Job Mode

Use the Job Mode key to toggle the mode of the job between Advanced and Basic.
When the job is set to Advanced Mode, then you have all the laser alignment func­tionality described in this document. When the job is set to Basic Mode, then you
have a subset of the functionality defined in this document. Refer to the Basic
Mode section on page 3-12 for a detailed description of the functionality available
in the Basic Mode.

Before switching modes, a warning message will be displayed asking you if this is
truly the operation to be performed. If you answer yes, then any data stored on the
job or any settings other than the defaults will be cleared and you will remain at the
Alt Main screen. If you answer no, then the operation is aborted and you will
remain at the Alt Main screen.

Machine Config

Use the Machine Config key to advance to the Machine Configuration screen
where the machine components for the job can be defined. Refer to the Machine
Configuration section on page 3-17 for more information.

Laser Align Method

Use the Laser Align Method key to define the alignment method for the job. Refer
to the Laser Align Method section on page 3-19 for more information.

Tolerance Type

Use the Tolerance Type key to define the alignment tolerance type for the job.
Refer to the Tolerance Type section on page 3-22 for more information.

Exit Laser Align

Use the Exit Laser Align key to exit the Laser Alignment program and advance to
the 2130 analyzer’s Home screen.

3-8 Horizontal Alignment

Laser Config

Use the Laser Config key to advance to the Laser Configuration screen where the
laser head and analyzer addresses can be reviewed and set, and the Laser Head A
and B locations can be set. Refer to the Laser Configuration section on page 3-23
for more information.

Job Manager

Use the Job Manager key to advance to the Job Manager screens where a new job
can be created from scratch using default job setups, a new job can be created using
the job setup from an existing job, selected alignment jobs can be deleted from the
analyzer, and jobs can be transferred to and from the PC. Refer to the Job Manager
section on page 3-34 for more information.

Job Flow

Use the Job Flow key to define certain job flow parameters for the job. These
parameters consist of entering thermal growth information, performing a foot pre­check, defining live move options, enabling a live move audible tone and flashing
LED option, and reviewing and averaging multiple acquisitions together. Refer to
the Job Flow section on page 3-42 for more information.

Print Job

The Print Job key prints a summary report of the current job to the Virtual Printer,
if the Virtual Printer is enabled under the General Setup screen of the System Firm­ware. A summary report includes job information, notes, soft foot data, and
reading set data (machine feet moves and Angle/Offset data). The report includes
only the first and last reading sets that were acquired. The summary report will be
similar to the report displayed on page 3-10.

3-9Alt Main Screen Function Keys

3-10 Horizontal Alignment

Job Reset

The Job Reset key allows the operator to “Clear Job Data,” “Load Default Values,”
or “Load Default Tolerances.”

Clear Job Data

Use the Clear Job Data function to clear all stored data and notes from the active
job. Before any data is cleared, a warning message will be displayed asking the oper­ator if this is truly the operation to be performed. If the operator answers yes, then
the data stored on the job will be cleared and the operator is taken back to the Main
screen. If the operator answers no, then the operation is aborted and you will
return to the Alt Main screen.

Load Default Values

Use the Load Default Values function to load job default parameters. Before any
defaults are loaded, a warning message will be displayed asking the operator if this
is truly the operation to be performed. If the operator answers yes, then the job
defaults are loaded and all job data is cleared and the operator remains at the Alt
Main screen. If the operator answers no, then the operation is aborted and the
operator remains at the Alt Main screen.

Load Default Tolerances

Use the Load Default Tolerances function to load default alignment tolerances.
Before any defaults are loaded, a warning message will be displayed asking the
operator if this is truly the operation to be performed. If the operator answers yes,
then the default alignment tolerances are loaded and the operator remains at the
Alt Main screen. If the operator answers no, then the operation is aborted and the
operator remains at the Alt Main screen.

3-11Alt Main Screen Function Keys

Basic Mode

When running the Basic Laser Align application in the 2130 analyzer, or when the
Job Mode in the Advanced Laser Align application is set to Basic, the functionality
described throughout this manual will be limited to the subset described in this sec­tion.

Laser Align Application Alt Main (Basic Mode)

Except for differences in the alignment job parameters available under the Alt
Main screen, the procedure for performing a basic alignment is exactly as it is for
an advanced alignment. The Alt Main screen is reached by pressing the Alt key on
the Main screen.

3-12 Horizontal Alignment

Basic Mode Function Keys

Notes

This option functions exactly the same as is does for Advanced Horizontal jobs.
Refer to the Notes section on page 3-180 for more information.

Job Mode

When a 2130 analyzer is running the Advanced Laser Align application, the Job
Mode soft key functions as described in the section “Job Mode ” on page 3-8. From
Job Mode, the user can configure the active job to be run in the “Basic Mode”.

When running the Basic Laser Align application in a 2130 analyzer, the only mode
of the laser alignment program which is available is the Basic mode, so the Job
Mode soft key is disabled.

Machine Config

Machine component names can not be changed in basic mode; therefore, the
option to do so is not available. All basic horizontal jobs use “Mach A” as the left
machine component and “Mach B” as the right machine component.

Laser Align Method

Use the Laser Align Method key to toggle the alignment method between the only
two options available in Basic mode: Auto Sweep (default) and Manual 4 Point.
Refer to the Acquiring Alignment Data section on page 3-82 for more information
about these two methods. In Basic mode:

• When Auto Sweep is selected, the Mode option can not be changed; there­fore, it is not available. All basic horizontal jobs use the Standard Mode.

• When Manual 4 Point is selected, the Sample Rate option can not be
changed; therefore, it is not available. All basic horizontal jobs use a Sample
Rate of 2. Also, the Sample Rate can not be changed from the Laser Head
Status screen.

Refer to the Laser Align Method section on page 3-19 for more information about
the Mode of operation and Sample Rate.

3-13Basic Mode Function Keys

Tolerance Type

Use the Tolerance Type key to toggle the alignment tolerance type between the
only two options available in Basic mode: Standard (default) and Jackshaft. Refer
to the Tolerance Type section on page 3-22 and the Tolerances section on page
3-193 for more information. In Basic mode:

• When Standard is selected, the Estimate F Dim option can not be changed;
therefore, it is not available. All basic horizontal jobs allow the program to
estimate the F dimension to be one half of the C dimension.

Exit Laser Align

Use the Exit Laser Align key to exit the Laser Alignment program and advance you
to the 2130 analyzer’s Home screen.

Laser Config

Use the Laser Config key to advance to the Laser Configuration screen where the
laser head and analyzer addresses can be reviewed and set. Refer to the Laser Con­figuration section on page 3-23 for more information. In Basic mode:

• The Laser Head A and B locations can not be changed; therefore, the
option to do so is not available. For all basic horizontal jobs, Laser Head A
must be located on the left machine and Laser Head B must be located on
the right machine.

Job Manager

Use the job Manager key to advance to the Job Manager screens where a new job
can be created from scratch using default job setups, a new job can be created using
the job setup from an existing job, selected alignment jobs can be deleted from the
analyzer, and jobs can be transferred to and from the PC. Refer to the Job Manager
section on page 3-34 for more information. In Basic Laser Align application:

• Jobs can not be transferred to and from the PC; therefore, the option to do
so is not available.

• The alignment tolerance table can not be transferred from the PC into the
analyzer. All Basic Horizontal jobs created in the Basic Laser Align applica­tion use the CSI default tolerance values available in the analyzer.

• Only Basic Horizontal jobs can be created; therefore, the option to create,
other types of jobs (e.g. Advanced Horizontal, Vertical, and Straightness
jobs) is not available.

3-14 Horizontal Alignment

• If accessing an external memory card, only Basic Horizontal jobs can be
viewed and edited; therefore, if the card were to contain any Advanced Hor­izontal jobs they would not be available.

Job Flow

Since thermal growth information is the only Job Flow parameter that can be spec­ified, the Job Flow option is not available. In Basic mode:

• If enabled, thermal growth information can only be entered at the feet.

• Only an FDI Foot Pre-Check can be performed, but only from the data
acquisition screen.

• Live moves can only be performed in the horizontal direction.

• The live move audible tone and flashing LED option is disabled.

• Results from multiple acquisitions can not be reviewed and averaged
together.

Thermal Growth

Use the Thermal Growth key to define whether or not thermal growth informa­tion at the feet is to be entered for the job. When selected, the selection is toggled
between being enabled and disabled (default). When this option is enabled, you
are able to input the amount of vertical and horizontal thermal growth at each
machine foot. Refer to the Entering Thermal Growth Information section on
page 3-56 for more information.

Print Job

The Print Job key prints a summary report of the current job to the Virtual Printer,
if the Virtual Printer is enabled under the General Setup screen of the System Firm­ware. A summary report includes job information, notes, soft foot data, and
reading set data (machine feet moves and Angle/Offset data). The report includes
only the first and last reading sets that were acquired. The summary report will be
similar to the report displayed on page 3-10.

3-15Basic Mode Function Keys

Job Reset

The Job Reset key allows the operator to “Clear Job Data,” “Load Default Values,”
or “Load Default Tolerances.”

Clear Job Data

Use the Clear Job Data function to clear all stored data and notes from the active
job. Before any data is cleared, a warning message will be displayed asking the oper­ator if this is truly the operation to be performed. If the operator answers yes, then
the data stored on the job will be cleared and the operator is taken back to the Main
screen. If the operator answers no, then the operation is aborted and you will
return to the Alt Main screen.

Load Defaults Values

Use the Load Default Values function to load job default parameters. Before any
defaults are loaded, a warning message will be displayed asking the operator if this
is truly the operation to be performed. If the operator answers yes, then the job
defaults are loaded and all job data is cleared and the operator remains at the Alt
Main screen. If the operator answers no, then the operation is aborted and the
operator remains at the Alt Main screen.

Load Default Tolerances

Use the Load Default Tolerances function to load default alignment tolerances.
Before any defaults are loaded, a warning message will be displayed asking the
operator if this is truly the operation to be performed. If the operator answers yes,
then the default alignment tolerances are loaded and the operator remains at the
Alt Main screen. If the operator answers no, then the operation is aborted and the
operator remains at the Alt Main screen.

Since the application cannot communicate with PC (for the Basic Align application
running in the 2130 analyzer) the only tolerance values available are the CSI
default values.

The Advanced Laser Align application, when configured to run in the Basic Mode,
can use User Defined tolerance values because the program can communicate
with a PC, and download tolerance tables.

3-16 Horizontal Alignment

Machine Configuration

From the Machine Configuration screen you can select the machine components
for the current job. The Machine Configuration screen is reached by pressing the
Machine Config key on the Alt Main screen.

Machine Configuration Screen

When this option is first selected, the machine type defined for the left machine will
be highlighted by a red box around the machine type by default. The default
machine types for the left and right machines are “Mach A” and “Mach B”.

Up, Down, Left, and Right Arrow keys

Use Up, Down, Left, and Right Arrow keys to select between each of the machine
types.

3-17Basic Mode Function Keys

When “Other” is selected as the machine type you can enter a machine name (up
to 7 characters in length). The following machine types can be defined for the job:

Machine Types

Machine Configuration Function Keys

Select Left Machine

Use the Select Left Machine key to set the left machine component to the machine
type highlighted by the red box.

Select Right Machine

Use the Select Right Machine key to set the right machine component to the
machine type highlighted by the red box.

3-18 Horizontal Alignment

Laser Align Method

From the Laser Align (Alignment) Method subwindow you can select the align­ment method for the current job. The Laser Align (Alignment) Method sub­window is reached by pressing the Laser Align Method key on the Alt Main screen.

Alignment Method Subwindow

3-19Basic Mode Function Keys

Laser Align (Alignment) Method Function Keys

Method

Use the Method key to select the alignment method. The choices are: Auto Sweep
(default), Dual Pass, Manual Sweep, Auto 4 Point, and Manual 4 Point. Refer to the
Acquiring Alignment Data section on page 3-82 for more information.

Mode

Use the Mode key, if the alignment method is Auto Sweep or Manual, to define the
mode of operation for the alignment method defined. When selected, the mode
is toggled between Standard (default) and Averaging.

The Standard mode of operation is the mode that is most often used during hori­zontal alignments. In this mode of operation, once the direction of rotation is
defined by the laser heads, any previous data stored is overwritten by any new data
acquired at the same angular position.

The Averaging 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 this
mode of operation, once the direction of rotation is defined by the laser heads, any
previous data stored is averaged with any new data acquired at the same angular
position if the laser head has been moved at least 20° in the reverse direction or a
full 360° sweep is performed.

Target Window

Use the Target Window key, if the alignment method is Dual Pass, to set the Target
Window. The choices are: 10%, 25%, 50%, 75%, or 100% (default). The Target
Window determines the size of the valid data window around the vertical centerline
of the other laser head's Position Sensing Detector (PSD) in which data is to be
acquired as the laser beam passes across the PSD. No data is acquired as the laser
beam passes across the PSD outside of the valid data window. Typically a Target
Window of 100% is sufficient, but for increased accuracy and repeatability you may
want to decrease the size of the Target Window to ensure that data is being
acquired as close to the PSD's vertical centerline as possible.

3-20 Horizontal Alignment