VIBRO-LASER VLSAT Operation Manuals

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OPERATION MANUAL

VIBRO-LASER

AVOID EXPOSURE

CONTENT

PREFACE

LIMITED WARRANTY

LITHIUM ION BATTERY LIMITED WARRANTY

SAFETY INSTRUCTIONS

LASER LIGHT SOURCE HANDLING RULES

CHARGING THE SENSOR

MAINTENANCE

INTENDED PURPOSE

SPECIFICATIONS

SYSTEM DESCRIPTION

PREPARATION FOR WORK

PRELIMINARY WORKS

SETTINGS

SENSOR UNIT READINGS

SOFT FOOT

HORIZONTAL ALIGNMENT

CARRY OUT MEASUREMENTS (9-3-12 METHOD)

CUT ANGLE METHOD

THERMAL EXPANSION CORRECTION

VERTICAL ALIGNMENT

SAVING DATA AND REPORT CREATION

INFORMATION ABOUT SYSTEM AND SOFTWARE

Thank you for your purchase of a VIBRO-LASER alignment system!

We are sure that you have made the right choice and hope that the system will not only meet your expectations but exceed them as well.

Before system operation it is important that you read and understand this manual, most signicantly the chapters on safety and maintenance.

This manual is intended to provide information on the various operations and control procedures for the software and hardware of the system.

ALWAYS ALIGNED™

Klim, Fedya, Misha, Olga, Vladimir, Mike & Megh

PREFACE

This product is manufactured with the greatest care following the VIBRO-LASER quality control system. Should the product fail within one (1) year from the date of purchase under normal usage conditions, VIBRO-LASER will repair or replace the product free of charge in accordance with our warranty policy as solely interpreted by VIBRO-LASER.

1. Using new or refurbished replacement parts.

2. Exchange the product with a product that is new or which has been manufactured from new or serviceable used parts and is at least functionally equivalent to the original product.

Proof of purchase date is required, and sent together with a copy of the original purchase document. Warranty is valid under normal usage conditions as described in the user’s manual included with the product. The warranty covers failure on VIBRO-LASER products that could be related to material and/or fabrication errors. The warranty is valid only in the country of purchase by the original purchaser. The warranty is not valid in the following cases:

• If the product is broken due to mishandling or incorrect operation

• If the product has been exposed to extreme temperature, calamity, chock or

high voltage.

• If the product has been modied, repaired or disassembled by unauthorized

personnel.

• Compensation for possible damage due to failure on VIBRO-LASER product

is not included in the warranty. Freight cost to VIBRO-LASER is not included in the warranty.

Note! Before delivery of the product for warranty repair, it is the responsibility of

the buyer to backup all data. Data recovery is not included in the warranty service and VIBRO-LASER is not responsible for data that may be lost or damaged during transit or repair!

LIMITED WARRANTY

LASER LIGHT SOURCE HANDLING RULES

Follow all the safety and control rules, regulation, procedures, and general common sense VIBRO-LASER is not responsible whatsoever for any injuries, loss of production or capacity, or any failure of any kind as a result of the user/owner not following instructions as set forth in this manual, on product labels, in their work area, or general industry practices and common sense. Do take notice of any warning labels on the device and in the operation manuals. Lack of the consideration to such warning labels may cause personal injuries and damage to the equipment.

Lithium ion batteries inevitably lose power during their lifetimes, depending on usage temperatures and the number of charging cycles. Therefore, the internal rechargeable batteries used in VIBRO-LASER products are not included in our general 1-year warranty. There is 6 months warranty for the battery capacity not to fall below 70 % (a normal change means that the battery must have more than 70 % capacity after more than 300 charging cycles). A 1 year warranty applies if the battery becomes unusable because of a manufacturing fault or factors that VIBRO-LASER could be expected to have control of, or if the battery displays abnormal loss of capacity in relation to use.

VIBRO-LASER system uses laser diodes with 1.0 MW output capacity, which

complies with the Class 2 standards of SS-EN-60825-1-1994. This class is

considered to be safe for operation providing the following precautionary measures are taken:

strictly follow safety rules during operation;

the device might be used only for its intended purpose;

do not use the device if it or its parts are damaged in any way;

do not open laser source blocks;

SAFETY INSTRUCTIONS

LITHIUM ION BATTERY LIMITED WARRANTY

It is only allowed to use the original power USB cables. Use of any other USB cables may cause personal injuries and damage to the equipment.

During the charging of S and M sensor units the charge LED indicator will illuminate.

After the indicator is o, please disconnect the adapter from the sensor units.

Attention! It is forbidden to charge the sensor units in an explosion-hazard area!

Do not use vibro-laser until the equipment to be aligned is veried

100% de-energized

Follow your facility/company lock out tag out equipment shutdown rules

MAINTENANCE

CHARGING THE SENSOR

The system should be cleaned with a lint free cotton cloth or cotton buds dampened with mild soap solution. Detector and laser windows, however, should be wiped with alcohol swabs or cleaning pad.

Do not use paper tissues as they may damage the surface of the detector;

Do not use acetone;

To insure proper operation and life keep your VIBRO-LASER product clean. It is best practice to clean the system after use.

do not look in the laser source when it is working;

do not direct laser beam into other people’s eyes;

All repair or calibration of the laser source may only be completed by

VIBRO-LASER or those authorized by VIBRO-LASER in writing.

INTENDED PURPOSE

SPECIFICATIONS

VIBRO-LASER shaft alignment systems are a portable high-precision device designed for alignment control of rotating machines (pumps, electric motors, reduction units, compressors, etc).

< 1 mW

Diode laser with wavelength 635nm, class II

up to 10 m

30 mm

Digital — CCD detector

0,001 mm

0,3% ± 7um

0.1

IP65

lithium-ion

up to 20 hours

Yes

SENSOR UNITS M and S

Anodized aluminium

90mm x 60mm x 32mm

Material

Dimensions

Laser power

Laser emission

Distance between blocks

Detector receiver length

Detector type

Detector resolution

Measuring accuracy

Digital inclinator

Protection class

Batteries

Time of operation

Bluetooth 4.0

from -0 º С to +60 º С

Operating temperature

LABELING

ON/OFF button (hold for 2-3

seconds to turn o)

Mini USB port (for charging)

Charge indicator (illuminates

green during charging then turns o)

Connection indicator (illuminates

blue when connects, blinks during transfer)

Clamping bar with screw

ON indicator (illuminates red when

ready for work, illuminates green when ready for measurements)

Adjustment screw (for vertical laser positioning).

Detector receiver

Laser beam window

Model, and Serial Number are printed on the

name plate on the back of sensor units.

SYSTEM DESCRIPTION

SENSOR UNITS M and S

1010

Fix the sensor unit with the M label to the movable part of the machine, and then x the S-labeled sensor unit to the stationary. Mounting each sensor for each side as shown below.

The sensor units should be xed with a shift (see the gure).

Note! Fix the sensors at a reasonable distance from eachother not beyond 10m

Place the v-bracket vertically on the shaft of the machine being aligned. Take the loose end of the chain and pull it to remove the whipping, then x it to the hook. (Fig. A)

Pull the chain tightly via the screw. Try to avoid excessive tightness. (Fig. B)

If the shaft diameter is too big, use extension chains or replace with common chains from any hardware store or industrial supplier to

make the chain longer. (Fig. C)

Clamping bars might be xed under units (recommended) as above

them. (Figг. D)

Correct the height of the units by slowly moving them along the bars

until the laser beam points to the center of the receiver of each unit. Fix the units with the locking screw on the сlamping bar. (You can ne tune the beams with the dial)

PREPARATION FOR WORK

Attention! M unit laser direction can be adjusted with the adjusting screw at the top of the unit. Normally, it is not required, but it may be needed if the distance between units is large.

Before the installation of the measurement system to the machine, check its

base, bolts and preinstalled shims. Check for restrictions (is there enough

space for moving the machine).

After the visual check proceed with the following:

Before start of the alignment check for following:

What are the alignment tolerances required?

Are there any thermal compensation requirements?

Are there any size restrictions for measurement system installation?

Are the shafts able to be rotated?

What size shims will be needed?

PRELIMINARY WORKS

Remove old and rusty shims (if removable);

(Fig. A) (Fig. B) (Fig. C) (Fig. D)

Check socket joint and loosen fasteners;

Check for soft foot;

Check how loose is the machine;

Check for run out of the shaft and the socket joint;

Check for pipe strain;

Check for end clearance between the shafts (axial alignment).

SETTINGS

Mount the sensor units on the shafts. Turn the S and M units on (the red LED indicator goes on). Turn the VIBRO-LASER software.

Touch the Icon “Global settings”

Attention! After initial use the sensor units will be automatically connected by default.

Touch the Icon “Sensor units search”

Choose Measurement Resolution.

Set the averaging lter from 1 to 20

Choose units of measurement (millimeters or inches). Choose between metric and imperial

measurement convention, and the necessary resolution (default setting is 0.01 mm or 0.4 mils).

Attention! If laser beam passes through air with variable temperature or in the case of signicant background noise, the beam directionality may be aected.

When connected, the indicators

will illuminate in blue.

SENSOR UNIT READINGS

Start the program by touching the Icon

«Sensor Unit Readings» in the main menu

During the program loading the display shows data received directly from the sensor units (position of the laser beam on the sensor and inclinometer angle).

If no value is available, the display shows

Variation of the results might be caused by instability of measurement process. Try reducing the intensity of air movement between laser and the detector (e.G. By replacing the heat sources or closing doors). If the results are still instable, increase the lter value. Default setting is 1. Most common values are from 1 to 3.

To reset the readings touch the Icon

Note! Before any alignment the soft foot (loose t of the base) should be addressed. Otherwise the results of a precision alignment will be inneective. The removal of the soft foot is impossible without any measuring devices. In your VIBRO-LASER embedded alignment program you are able to provide to identify and correct soft foot.

Set the units to the 12 o’clock (the green LED indicator of M and S units will glow green).

Check bolt tensioning of each foot.

Before Soft Foot process you need to enter following dimensions: distance between bars; distance between M unit and rst set of feet; distance between the rst and the second sets of feet.

Touch the Icon “Next”

Touch the Icon “Soft foot”

SOFT FOOT

Choose the bolt by touching the Icon

First loosen the chosen bolt completely, then tighten it rmly. It is recommended to use a torque wrench for tightening.

Save the measurement result by touching the “OK” Icon

Repeat these actions for other bolts.

Values show shim plate thickness to eliminate the soft foot.

Note! You can carry out new measurement at any time by touching the corresponding Icon.

To reset measurements touch the Icon

Make the required corrections then check each foot once more.

Note! Allowed values from 0mm to 0.06 mm

Touch the icon “Horizontal alignment”

in main men

Complete the alignment procedure step by step, following the arrow

indicator.

Note! You can backup to the horizontal alignment menu anytime to conrm your step.

HORIZONTAL ALIGNMENT

Insert the dimensions

Touch the icon to insert the dimensions.

Touch the icon

Insert the tolerance values according to the rotation rate of the machine.

CARRY OUT MEASUREMENTS (9-3-12 METHOD)

This type of measurement requires rotating the shaft with the M and S units

in such a way that ag indicator on the information circle is in the green zone (3-6-9-12o’clock).

Set the M and S sensor units to the 9 o’clock green zone in such a way that they have roughly the same angles (control the angles of M and S sensor units via the virtual level).

Note! For results please take measurements in at least three of four possible

control positions.

• Distance between the BARS CENTRES OF M and S UNITS

• Distance between the center of coupling joint and the BAR CENTER of M unit

• Distance between M unit and the rst set of feet (support).

• Distance between the rst and the second set of feet (support).

Touch the Icon

The eld activates a calculator interface. To submit the inserted dimensions, touch ОК.

Use the supplied tape measure for measuring:

Tap the measurement icon

The second measurement is registered in the table.

Turn the shafts to the 12 o’clock

Touch the Icon

The rst measurement is registered in the table.

To reset the data, touch the Icon

Turn the shafts to the 3 o’clock.

Results of measurements

Touch the measurement icon

The third measurement is registered in the table.

Touch the Icon

To adjust the shafts position vertically, rotate the shafts to 12 or 6 o’clock.

To set the M and S sensor units, use the displayed virtual levels. Adjust the machine’s vertical position until the values are within the allowable limits. Arrows next to the feet show the direction to move the machine in real time.

Live Alignment Mode

This screen shows the misalignment values according to the coupling joint

and the feet position (horizontal as well as vertical). Symbols on the left of the

value indicate angular and parallel misalignment and bias directions, as well as indicates whether the values are within the allowable limits.

Note!. The symbols above show whether the misalignment and bias values are within the selected tolerances.

Symbols next to the soupling joint REPEAT THE LIMIT READINGS.

Within the tolerance limits (green)

Within the tolerance limits

Within the doubled tolerance limits

Beyond the doubled tolerance limits.

Within the doubled tolerance limits (yellow)

Beyond the doubled tolerance limits (red)

Touch the Icon

Note! First adjust the position of the machine vertically, then horizontally.

Note! Use VIBRO-LASER SHIMS to align the machine vertically.

To adjust the shafts position horizontally, rotate the shafts to 3 or 9 o’clock.

Use the displayed virtual levels for precise alignment. Adjust the machine’s

horizontal position until the values are within the allowable limits according

to the arrows next to the feet.

Note! Tighten the foot bolts crosswise with same force using a calibrated torque wrench to avoid changes of results!

Carry out the verication measurement using the Clock method. After the verication measurement the Horizontal Alignment menu is opened.

Note! To carry out more precise alignment after the verication measurement use the Live Alignment to continue align.

The alignment is complete

To carry out

the verication measurements touch

CUT ANGLE METHOD

If 180 degree rotation of the shaft is impossible for some reason, please use the CUT ANGLE METHOD.

The minimal rotation required is 40 degrees. The more rotation, the better and more precise the alignment.

Save results, touch the Icon

Touch the Icon

Start measuring from any point. Rotate shafts in the next position according to the animation.

The rst measurement is registered in the table. Rotate shafts in the next position according to the animation.

Touch the measurement Icon

The second measurement is registered in the table. Rotate shafts in the next position according to the animation.

The third measurement is registered in the table.

Attention! When taking measurements, rotate the shafts so the sectors do not overlap each other

Note! For the best accurate maintain the sensors with maximum distance.

Note! When using this method the shafts should be connected to provide maximum precision of the measurements and the alignment.

Touch the Icon

Touch the icon in the alignment screen

Insert the correction via calculator

During the operation the equipment is exposed to various factors and forces.

The most common inuence on alignment is change of the machine temperature which leads to the enlargement of a shaft and subsequent misalignment. This process is called thermal expansion or growth.

To compensate the thermal expansion you need to make a correction for the expansion of the cold machine during its heating through out operation.

THERMAL EXPANSION CORRECTION

When the results are received, the sign is shown,

indicating that the thermal correction is made.

Complete the alignment procedure step by step, following the arrow indicator.

Note! You can open the vertical alignment menu at anytime to verify your step

Vertical shafts alignment is carried out by moving the machine ange/coupling until the axes are coaxial enough to stay in the assigned limits. The system is able to work with an allowance table.

VERTICAL ALIGNMENT

Touch the Icon

Insert the tolerance values according to the RPM of the machine.

Touch the icon to insert the dimensions.

VThe eld activates a calculator interface. To submit the inserted dimensions, touch ОК.

Use a measuring tape for measuring:

The vertical alignment program calculates the machine position by

measurements in three shaft positions when they are rotated 180°.

Distance between the BARS CENTERS OF M and S UNITS Distance between the center of coupling joint and the BAR CENTER of

M unit Distance between the centers of outer bolts.

Number of bolts (it is helpful to use a paint market or grease pencil to

mark the machine with the applicable bolt number for future

The rst measurement is registered in the table.

Rotate shafts in the next position according to the animation.

Touch the measurement icon

The second measurement is registered in the table. Rotate shafts in the next position according to the animation.

The third measurement is registered in the table.

Touch the button

to get the measurement result

The measurement results screen shows the misalignment values according to the coupling joint in both directions. Symbols on the left of the value stand for parallel and angular directions and also indicates whether the values are within the allowable limits.

Touch the measurement icon