Manual En Inglés - Avv701pro - Completo

KOHTECT AVV-701 LASER SHAFT ALIGNMENT SYSTEM OPERATING INSTRUCTIONS MANUAL KOHTECT(c) 2013

CONTENT 1. General and introduction ......................................................................................................................... 5 1.1 Laser Safety Precautions .................................................................................................................... 5 2. Technical Description .............................................................................................................................. 6 2.1. Designation ....................................................................................................................................... 6 2.2. Specification and Features ................................................................................................................ 6 2.3. System Package. ............................................................................................................................... 7 2.4 Misalignment Parameters .................................................................................................................. 8 3. Machine Alignment ................................................................................................................................. 9 3.1 Input Measurement Data .................................................................................................................. 10 3.2 Set-up the Device ............................................................................................................................. 10 3.3 Connecting the Measuring Units ..................................................................................................... 10 3.4 Input of Dimension .......................................................................................................................... 10 3.5 Rough Alignment Procedure ........................................................................................................... 12 4. Getting Started ....................................................................................................................................... 14 4.3 Horizontal Machine Alignment ....................................................................................................... 14 Input dimensions ................................................................................................................................ 14 Change parameters ............................................................................................................................. 15 Biaxial and “uniaxial” adjustment modes.......................................................................................... 16 Collect data ........................................................................................................................................ 16 View and edit the points .................................................................................................................... 17 To call collect data popup menu ........................................................................................................ 18 Calculate alignment results ................................................................................................................ 19 Shim simulation ................................................................................................................................. 20 Thermal growth.................................................................................................................................. 20 Setup tolerances ................................................................................................................................. 21 4.3.2 To start correction for the misalignment................................................................................... 21 4.3.3 To save alignment measurement data ....................................................................................... 22 Quit program ..................................................................................................................................... 22 4.4 Vertical Machine Alignment ........................................................................................................... 23 Input dimensions ................................................................................................................................ 23 Change parameters ............................................................................................................................. 24 Collect data ........................................................................................................................................ 24 Calculate alignment results ................................................................................................................ 25 4.4.1 To start correction for the vertical misalignment..................................................................... 25 4.4.2 To save alignment measurement data ....................................................................................... 26 4.5 Program for Soft Foot check and correction .................................................................................... 27 Input dimensions ................................................................................................................................ 27 Take measurement ............................................................................................................................. 27 To save soft foot result....................................................................................................................... 28 4.6 Bore Center Line Program ............................................................................................................... 29 Unit‟s configuration ........................................................................................................................... 29 Measurement preparation .................................................................................................................. 29 To start bore centerline program ........................................................................................................ 29 Set parameters .................................................................................................................................... 29 Take measurement ............................................................................................................................. 30 Evaluate result.................................................................................................................................... 31 Live adjustment.................................................................................................................................. 31 KOHTECT(c) 2013

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Save result .......................................................................................................................................... 32 4.7 Flatness Program.............................................................................................................................. 33 Select grid shape ................................................................................................................................ 33 Setup grid parameters ........................................................................................................................ 34 Select data source.............................................................................................................................. 35 Taking measurements ........................................................................................................................ 35 The result display ............................................................................................................................... 36 Circle shaped plane ............................................................................................................................ 37 Setup circular grid parameters ........................................................................................................... 37 Taking measurements ........................................................................................................................ 38 The result display ............................................................................................................................... 38 To save data ....................................................................................................................................... 39 Quit flatness program......................................................................................................................... 39 4.8 Squareness Program ......................................................................................................................... 40 Set parameters .................................................................................................................................... 40 Taking measurements ........................................................................................................................ 41 Measurement result ............................................................................................................................ 42 To save data ....................................................................................................................................... 42 Quit squareness program ................................................................................................................... 43 4.9 Straightness Program ....................................................................................................................... 44 Straightness measurement.................................................................................................................. 44 Setup parameters ................................................................................................................................ 44 Set measurement points number ........................................................................................................ 44 Set dimensions ................................................................................................................................... 44 Define a splice ................................................................................................................................... 45 Switch between manual data and data from detector ........................................................................ 45 Laser beam adjustment principle ....................................................................................................... 45 Carrying measurements ..................................................................................................................... 45 Evaluate measurement results............................................................................................................ 46 Splice concept .................................................................................................................................... 46 Step by step instruction to start measure new splice ......................................................................... 47 The Live move mode ......................................................................................................................... 48 To save data ....................................................................................................................................... 48 4.10 Cardan program ............................................................................................................................. 49 Input dimensions ................................................................................................................................ 51 Collect data ........................................................................................................................................ 52 Calculate alignment results ................................................................................................................ 53 To start corrections for the misalignment .......................................................................................... 53 To save data ....................................................................................................................................... 53 Quit cardan program .......................................................................................................................... 55 4.11 Spindle program ............................................................................................................................. 56 Input distances ................................................................................................................................... 56 Taking measurement .......................................................................................................................... 56 Evaluate results .................................................................................................................................. 57 To save data ....................................................................................................................................... 58 5.0 Standards Tolerance of Shaft Misalignment ........................................................................................ 59 6.0 Delivery Set ......................................................................................................................................... 59

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1. General and introduction 1.1 Laser Safety Precautions The KOHTECT AVV-701 alignment system is the class II laser device at typical wavelength of 670nm, delivered output power of less than 1 mW and maximum radiant energy per pulse of 0.1 mJ. The Class II laser comply with requirement outlined by USA‟s FDA as well as international ANSI, BS 4803 and IEC 825 standard. Be sure to follow the following safety precautions to avoid personal injuries and damage to the system Do not look directly into laser the beam at any time! Do not direct laser beam on to the people‟s eyes!

ATTENTION! Do not try open / dismantle measuring units and the display unit – this can damage the system, and your after-sales service warranty will come void. Warning! Be sure the machines to be measured, cannot be started unintentionally as this can cause injuries. For this purpose, before the mounting of equipment, either block the power switch in the “Off” position or remove the safety fuses. These precautionary rules must be followed until the measuring system is dismantled from the measured machine.

INJURY RESPONSIBILITY DISCLAIMER Neither the NPP KOHTECT enterprise nor our authorized dealers are liable for the damages caused to machinery or equipment by use of the AVV-701 system. We carefully check text of this manual to eliminate errors, nonetheless there may be mistakes or inaccuracy involved. We will be grateful for your reporting to us about any error, and we will be able to correct them in the subsequent editions of the manual.

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2. Technical Description 2.1. Designation AVV-701 alignment system (C911 sub-system) (further as System) is designed for: checking of shaft alignment of mechanisms; estimation of the surface flatness. The checking of shaft alignment means adjustment of the relative position of two coupled machines (e.g. motor and pump) so that the centre line of the axis will be concentric when the machines are running during normal working conditions.

2.2. Specification and Features 2.2.1. Separation distance between measuring transducer units, up to 10m 2.2.2. Display control operating temperature range, -10..+55 degree C 2.2.3. Measurement accuracy, 1%+0.01 2.2.4. Laser type: Visible red 635-670 nm, <1 mW 2.2.5. Detector type: Positional-sensitive photodiodes, 10х10 mm 2.2.6. Display resolution, 0.01 or 0.001 mm, (1 or 0.1 mil ) 2.2.7. Measuring resolution, 0.001mm 2.2.8. Electronic inclinometer resolution, 0.1 degree 2.2.9. Power supply: Rechargeable NiMH battery 2.2.10. Gross weight, 7.5 kg 2.2.11. Built-in application programs and options: horizontal shaft alignment at any 90º shaft position; vertical shaft alignment; Setup options; horizontal shaft alignment with rotation angle less than 120º; Soft foot; thermal growth; selection of shimming simulator to calculate for expected alignment;

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2.3. System Package. The System includes (Fig. 1): AVV701 display control unit two measuring transducer units universal chain brackets for mounting of the measuring units measuring tape, mm/inch 220 Volts AC charger connecting cables; CD-ROM PC software USB PC communication cable Operating instructions manual in CD Carrying case with form-inserted

* Top positions to be faced up while setting up both the transducer. Datum lines for measuring of dimension input

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2.4 Misalignment Parameters Misalignment of any rotating machine is expressed in parallel (Offset) and angular (Gap) of the shafts. Most frequently in practice, both of them are present simultaneously. Different kinds of misalignment of axes are shown in Fig. 2.

Parallel misalignment of axes – Offset (displacement) Angular misalignment of axes – Gap Parallel and angular misalignment of axes – (Offset + Gap) Fig 2 The parallel (Offset) and angular (Gap) misalignment of axes is determined in two mutually perpendicular planes. For the purpose of elimination of the parallel and angular misalignment of axes, in each of the planes a correction of position of the movable machine (M) will be done. For the horizontal mounted machine – the movable machine (M) position is adjusted in the horizontal and vertical planes. For the vertical mounted machine, operator determines arrangement of the correction planes, basing on considerations of the convenience and technological effectiveness of moving of the movable (M) machine. Stationary machine (S) - in the process of eliminating of the axes misalignment the position of this machine stay static, i.e. it does not move. Movable machine (M) – the machine, which position is adjusted for eliminating of the parallel and angular misalignment of axes. The measurement system calculates the values of the angular and parallel misalignment of axes in the plane of the coupling (in two mutually perpendicular planes), and the adjustment values for the machine feet on the movable (M) machine, that is necessary for elimination of this misalignment of axes. Fig. 3 shows misalignment of axes and the values for its correction just for vertical plane.

Fig 3.

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3. Machine Alignment   

Mount the Measuring transducer units on the shafts of the (S) and (M) machines Select program according to the application of machine to be measured Input the distances between the (S) and (M) units, the coupling and the movable machine feet



Press to record readings from the measuring units at three different positions of the shafts Adjust the machine feet position of the movable machine in accordance with correction results of the calculated value on control screen Save the measured result into the file

 

While making the measurement, it is may be necessary to observe and understand the orientation and rotation direction of the shafts with the (S) and (M) measuring transducer units with regard to the relative position of the (S) and (M) machines as in Fig.4.

Fig 4. Fig. 4 shows the view of (S) machine from the (M) end view, at the 12:00 o‟clock position. The measuring transducer units have marking (S) and (M) on the top of each unit, should be mounted with brackets onto the shafts of the (S) stationary and (M) movable machine respectively.

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3.1 Input Measurement Data AVV-701 system function is based on the measurement of the laser beam movement on the detector receiver‟s window during the turning of shafts with the measuring units mounted. To enable the System to carry out the shaft alignment calculation, it is necessary to record the measurement data in at least three positions of the shafts rotation. Turning the shafts in the range of 180º is sufficient, but for the best results turn as wide as possible recommended. If design features of the machines do not make it possible to carry out rotation of the shafts with the measuring units mounted up to 180º, the instrument also provides smaller shaft rotation angle measurement mode that allows possibility to enter the measuring data when the shafts rotation angle constitutes as low as 60º, note turn as wide as possible always recommended. System‟s advanced multipoint mode allows shafts rotation in any direction and up to 36 points.

3.2 Set-up the Device Before the beginning of the work, check the battery voltage and charge it if necessary. Battery voltage is indicated on the display of the device in the main menu. The device is automatically turned off when the voltage is lower than 4.6 V. Check and clean if necessary the surface of detectors and aperture of laser. Use soft tampons, moistened with alcohol, for the cleaning. Solvents must not be used! Check and setup if necessary, date and time of the system clock.

3.3 Connecting the Measuring Units There are two connectors in the Control Display unit and each Measuring transducer units. Connection to the Control Display unit is arbitrary, i.e. the units can be connected either in parallel or in series (Fig. 5) with any of the two cables contained in the set, to any of the connectors in the Control Display unit and the Measuring transducer units.

Connecting the measuring units in parallel

Connecting the measuring units in series Fig. 5

3.4 Input of Dimension To enable the AVV-701 to carry out accurate calculations it is necessary to input the distances between the measuring transducer units, the coupling and the machine feet. KOHTECT(c) 2013

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Fig. 6 shows the dimensions input for the horizontal plane alignment. Fig. 7 shows the dimensions input for the alignment of vertical flange mount machine.

Fig 6.

S-M distance between measuring transducer units. S-C distance between S and center of coupling. S-F1 distance between stationary detector (S) and the feet pair 1 (F1). S-F2 distance between S and F2 (must be longer than S-F1). If the machine has three pairs of feet, you can change this distance after finished measurement, and then repeat the calculation and get a new adjustment value for this pair.

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Fig 7. S-M distance between measuring transducer units. S-C distance between S and center of coupling. S-F1 distance between stationary detector (S) and the plane of alignment (F1).

3.5 Rough Alignment Procedure Rough alignment should be applied only when the alignment is extremely poor, the laser beams may travel outside the detectors during rotation of the shafts with the Measuring units mounted. If this happen it is necessary to do a rough alignment first. Rough alignment procedure (variant 1), (Fig. 8): Turn shafts with measuring units to the 9 o’clock position. Aim the laser beams at the centre of the closed detectors. Turn shafts with measuring units to the 3 o’clock position. Check where the laser hits, then using the laser adjustment screws, adjust the beam half the travel in direction to the centre of the target (Fig. 8). Adjust the movable machine so that the laser beam hits the centers of both the targets, (S) and (M). Follow the regular procedure to continue.

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Fig 8. Rough alignment procedure (Variant 2): Turn the shafts with measuring units to the 9 o‟clock. Apply the targets in the view of scaled paper sized 50 x 50 mm to the detector surface. Aim the laser beams at the centre of these targets. Switch the display unit into the mode of manual data input. Turn the shafts with measuring units to the 12 o‟clock position and enter the values of laser beam at the 12 o‟clock position, then turn the shafts to the 3 o‟clock and enter the values of laser beams at the target marking. The system will calculate roughly the offset value and adjustment value for movable machine (M). Adjust the movable machine according to the results of calculations. Follow the regular procedure to continue. While entering manually the values of the position of laser beam at the target, take into account the sign (Fig. 9)

View of a target (M) at the 12 o‟clock position

View of a target (S) at the 12 o‟clock position

Fig 9. KOHTECT(c) 2013

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4. Getting Started To start AVV-701:  In Main Menu by using the arrow keys move the selection bar to “Alignment” then press . The display shows alignment menu screen with programs option as in Fig.10. The lower section display the day, date and time of system clock, and the battery charge power within the device.

4.3 Horizontal Machine Alignment Mount the Measuring transducer marked with (S) on the shafts of the stationary machine and Measuring transducer marked (M) on the moveable machine. Connect the cables as per section 3.3, between the Measuring transducer units and Control Display unit. Select “Horizontal” to enter horizontal alignment program, then press Press

to start new alignment task or press

.

to resume saved task.

Important! During alignment measurement: DO NOT change the positions of measuring units at the time of interruption of the work; DO NOT move the movable machine when the device is turned on.

Input dimensions Dimensions between the two transducers(S-M), between S unit and coupling center (S-C), between the S unit and the front feet of moveable machine (S-F1) and between the S unit and the rear feet of moveable machine(S-F2) should be entered. KOHTECT(c) 2013

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measure units MA means manual angle IA means use inclinometer MD means manual data LD means use transducers data 2D means biaxial adjustment mode 1D means “uniaxial” mode

Use data.

or

to move from dimension to dimension to input or reconfirm all dimension

To start input dimension use to enter desired value then press

key, when the blinking cursor appeared use numeric key pad to confirm.

Change parameters To change parameters call popup menu by press of When popup menu appears use

key

to select between inclinometer and manually entered

angle, use to select between transducers data and manually entered data, use select between biaxial and “uniaxial” alignment mode.

to

MA means manual angle IA means use inclinometer MD means manual data LD means use transducers data 2D means biaxial adjustment mode 1D means “uniaxial” mode

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Biaxial and “uniaxial” adjustment modes When biaxial mode used both vertical and horizontal transducers data used in live adjustment mode to perform live adjustment. Shafts rotation not needed and strictly prohibited to adjust moveable machine in vertical and horizontal planes. “uniaxial” means traditional live adjustment mode where you should turn shafts to predefined transducers position to perform vertical or horizontal adjustment. The position should be 12 or 6 o‟clock for vertical adjustment and 3 or 9 o‟clock for horizontal adjustment.

Collect data AVV-701 system does collect data in advanced multipoint mode. Up to 36 points using any shafts rotation direction can be stored for the best results. At least three points should be stored. To start collect data press The laser beams turned on now. Screen of wait connection to transducers appears. Note that Bluetooth connection need more time for connection to be established. If connection cannot be established during more than 90 seconds check if pin codes entered or check transducers.

Transducers serial numbers become available when connection established

After the connection has been established data collect screen appears Using fine adjusting screws on the Measuring transducers, adjust the laser beams to the centers of detectors shutter cover one at a time, refer Fig. 1a & 1b. Once laser is centered on both transducer, open the shutters. The screen starts display detectors coordinate position readings for both transducers (S) & (M) Face the stationary machine from the movable machine.

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Stored or manually entered Y values

Main clockface with stored points showed

Stored or manually entered angle

Selected point index

Current angle

R means we currently view already stored point

Current Y values

To store current point press Blinking outer circle means minimum turn violation If minimum turn requirement not satisfied then hint shows minimum turn required The minimum turn between points(>10º) should be respected. Up to 36 points can be stored NOTE: to achieve acceptable results the whole shafts turn must not be less than 60 degrees.

View and edit the points Each of the points can be viewed, replaced or deleted. To increase selected point index press and to decrease selected point index press sign blinks at the left bottom corner of the screen. To delete selected point press

You can edit point only when „R‟

(you should not be in manual value edit state)

Delete confirmation dialog will pop up. To confirm point deletion press To replace selected point in the manual data mode enter new manual data and confirm by press

Replace confirmation dialog will pop up. To confirm value replacement press

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Replace confirmation dialog press

to confirm

To replace selected point when transducers data used press

and

confirm replacement.

To call collect data popup menu press

. Then

To change display resolution between 2 and 3 decimal digits press To enable or disable input data filter press round robin fashion by press

you can change filter averaging number in the

. To reset filter press

.

If manual angle used press to enter angle value press to confirm. When manual angle entered and manual data mode is choosed then cursor switched to enter M and S Y values automatically. So to enter all manual values press to confirm then enter M Unit value then press

then enter angle then press

to confirm then enter S Unit value then press

to confirm. If manual data used press

to enter M unit value then press

to enter M unit value then press

to confirm and then press

to confirm. Filter averaging value

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Calculate alignment results When all of the desired points gathered press live adjustment

to go to view calculated results and to make

Note: Screen message show “Do not turn shafts while aligning”

The alignment measurement result of calculations shows the values of the angular “Gap” and parallel “Offset” misalignment in the plane of the coupling (in Horizontal and Vertical planes) as well as the correction values for the machine feet F1 (machine front feet) & F2 (machine rear feet) on the movable (M) machine that are necessary for eliminate the horizontal and vertical misalignment. STOP means live adjustment now off use

for change

‘!’ indicates tolerances violation

Note: For the purpose of clarity the values of parallel Offset and angular Gap misalignment in the plane of the coupling are shown in the view of the symbols of half-couplings. The adjustment values of the position of the feet F1 and F2 of the machine (M) in the horizontal plane indicate the value of horizontal shift. The positive values mean that the feet must be pushed, the negative values – the feet must be pulled. The adjustment values of the position of the front feet F1 and F2 of the machine (M) in the vertical plane indicate the value of vertical shift. The positive values mean that the feet must be lifted, the negative values – the feet must be lower. Press to freeze the alignment result on screen to temporary jot down of coupling results, Fig 19a, while prepare for live adjustment. To resume “live” measuring mode, Fig 19b, on machine, press again and start shimming and adjust horizontal movement with under the live adjustment mode.

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Note: To view option features(pop up) in Fig.19e, press and hold For prompts screen message on the function key, press for show following info: – to toggle resolution 0.01mm or 0.001mm – «Shim simulator» – to check the shimming which size is different from the results of calculation (Fig.19c). – “Thermal growth” – to enter compensation values to thermal growth (Fig.19d ). – to save the result. Enter «My Documents》. You may save this file in the old folder or create a new folder.

Shim simulation The shim simulation allows easy and convenient way to evaluate rest misalignment when shim added or removed. To open shim simulation press

.

Values in brackets shows calculated results need to compensate misalignment

Press

to enter shim value for the front foot

Press

to enter shim value for the rear foot

Use

to confirm entered value

See rest misalignment here

Thermal growth Most machines develop a certain amount of heat while running. In the best case both the driving and the driven machine are affected equally requiring no input of compensation values. But in several applications the driven machine is either hotter, i.e. a pump for hot liquid, or cooler than the driving machine. The machine manufacturers define the thermal growth of the machines differently, but in most cases you will find it as a factor of deliberately misalignment expressed in parallel offset and angular error KOHTECT(c) 2013

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To enter thermal growth press

.

Press

to enter horizontal offset value

Press

to enter horizontal gap value

Press

to enter vertical offset value

Press

to enter vertical gap value

Use

to confirm entered value

Setup tolerances To setup tolerances call options menu by press Use

and then press

for cyclically change rpm, include set to OFF state

4.3.2 To start correction for the misalignment To correct the horizontal and vertical plane in biaxial as per obtained coupling result in, press to switch frozen result screen to “LIVE” mode with shaft remain at last recording clock position. Loosen moveable machine feet and start adjust the feet correction values (add or remove shims) according, and at the same time adjust the machine horizontal movement at feet (push or pull using jacking bolt if any ) according to “LIVE” horizontal correction reading. There are some differences when “uniaxial” mode used. For live adjustment in “uniaxial” adjustment mode: freeze result screen if required(use key). Turn shafts to the 12 o‟clock transducers position. Switch to LIVE mode and perform machine vertical movement(add or remove shims). Do not move machine in the horizontal plane at the same time. When machine vertical movement done press to freeze result screen. Turn shafts to the 3 o‟clock transducers position. Switch to LIVE mode and perform machine horizontal movement(push or pull using jacking bolt if any). Do not move machine in vertical plane at the same time. When machine horizontal movement done press

to freeze results screen.

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4.3.3 To save alignment measurement data When measurement finish, press Press

to enter file save display.

again to save the alignment result main directory or

to make new directory or select the existing directory to save.

Quit program When quit the program: - press

to backup changes in measured data.

- press

to discard changes.

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4.4 Vertical Machine Alignment The vertical machine alignment program shares many similarities with horizontal machine alignment. See also: horizontal machine alignment Select “Vertical” to enter vertical alignment program, then press Press saved task.

.

to start new alignment task or press

to resume

Mount the Measuring transducer units on the shafts of the machines (S) and (M) as shown in Fig. 20a. Note: Mark the clock positions 9-12-3-6 at the flange. Using the connecting cables, connect Measuring transducer units and Control Display

Input dimensions Input diameter here

Input bolts number here

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Input the first dimension between the two transducer units, Fig.20a. Press. dimension then input the new dimension follow by

to start input

to confirm input data.

Use or to move to 2nd dimension input, distance from Measuring transducer (S) unit to coupling center, Fig 20b. Use or to move to 3nd dimension input, distance from Measuring transducer (S) unit to flange face, Fig 20c. Use

or

to move to 4th dimension input, flange bolt center distance.

Use

or

to move to last dimension input, number of bolts.

Change parameters Same lake in horizontal alignment program, to change program parameters press popup menu Note: inclinometers cannot be used in the vertical machine alignment

to call

Press to switch between transducers data (LD) and manual data(MD) Press to switch between biaxial (2D) and “uniaxial”(1D) live adjustment

Press

when you enter all dimensions and set parameters.

Collect data Like in the horizontal alignment wait connection screen appears

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The display shows information of the serial number on both Measuring transducer units to identify device is connected properly. When connection established system switch to collect data.

Refer to horizontal collect data as the procedure mostly the same, except that the angle always entered manually(inclinometers not used). All important things specified for the horizontal alignment should be preserved

Calculate alignment results When all of the desired points gathered press live adjustment

to go to view calculated results and to make

Vertical alignment results shares many similarities with horizontal alignment results, except that there are no vertical or horizontal planes here, but plane “9-3”and plane “6-12” defined instead. Also flange shim results can be viewed using All important things specified for the horizontal alignment should be preserved As inclinometers not used care must be taken in “uniaxial” adjustment mode about that shafts must be settled in proper position before start of adjustment.

4.4.1 To start correction for the vertical misalignment Press Screen message show “Do not turn shaft while aligning” before display shimming values required for each individual bolts and make angular adjustment by adding in or remove shims as per display values. To freeze the result screen and LIVE adjustment mode, press toggle. Hand tight all bolts when shims adjustment done.

to

Press to toggle between offset adjustment (in 9-3 and 6-12 planes) and shims adjustment screen. Move the (M) machine along 9-3 and 6-12 direction as per offset adjustment values display on screen.

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Press to repeat the entire vertical measurement task again to confirm machine alignment has been done.

4.4.2 To save alignment measurement data When measurement finish, press

to enter file save display. Press

again to save the alignment result main directory or press make new directory or select the existing directory to save.

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4.5 Program for Soft Foot check and correction Check the machine for the soft foot before fulfilling any alignment adjustments. Form the alignment menu select “Soft foot” and press

Press saved task.

to start new soft foot task or press

to resume

Input dimensions You must check/input all the required machine dimensions before continue. See horizontal alignment input dimensions Note: Don‟t select manual input of data or angle

Take measurement Wait until connection to sensors has been established

Screen message: “ Wait … shaft should be in pos. 12 O „cl” to required shafts to turn to 12 o‟clock position to start soft foot measurement.

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Follow screen prompts message, release 1st bolt and wait approximately 5 second for soft foot value to measure. Then press key to record the value. Tighten the bolt as screen prompts message, and press to move to next bolt and repeat procedure as per prompts message on the display until all the four individual feet soft foot readings are taken on display. The result shows the difference between the released and tightened bolts of the foot. Set maximum shimming values. Choose to repeat entire soft foot check after remove the soft foot as per measured result.

To save soft foot result Press

to enter data save screen and press

soft foot reading or press existing directory to save.

Press

again to save

to make new directory or select the

to quit soft foot program.

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4.6 Bore Center Line Program The AVV-701 laser alignment system uses a visible laser beam to determine the relative the relative centerline of a series of bores. The laser transmitter(emitter of the laser beam) is mounted a one end of the machine and is aimed at the laser receiver(detector of the laser beam), which is mounted near the center of each bore in turn. The receiver is mounted on a special bracket which allow the freely rotation of receiver within the bore.

Unit‟s configuration “S” unit – laser transmitter (fixed position) “M” unit – receiver (on bore bracket) M” label should be on top side at 6h o‟clock pos.

Measurement preparation Thoroughly clean the bores to be measured Ensure that the boring machine(or bores) are readily moveable horizontally and vertically

To start bore centerline program To start “BoreCenterLine” program press

.

Press to start new soft foot task or press saved task.

to resume

Set parameters Press

to enter bores number from 3 to150

Press not

to switch between all distances between bores equal or

Use them

to select bores pair for enter distance between

Press

to start enter distance, use numeric keypad to enter value and confirm input by

press Note: when all distances equal selected AVV-701 automatically set all distances to entered value, so enter distance only once KOHTECT(c) 2013

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Press to change measurement configuration – number of receiver positions where data will be taken. In case of “3 points” configuration it is recommended to enter bores diameters (3: Diam.) it improves result precision. However if diameters are not entered, result calculation is still possible. In case of “8 points” – result is calculated with higher precision due to averaging.

Press to set Horizontal or Vertical bores orientation. In case of Vertical – inclinometer will not work. One should check measurement position manually. Press

to switch between use sensor data or manual data input

Take measurement Press

to begin measurement. Sensor data Plane number Measurement position data

Inclinometer data

Plane number

If sensor position differs from proper measurement position warning start blinking. (If inclinometer is ON)

Bore center displacement

Measurement position indicated on screen by radial line. Current receiver (“M”) inclination is indicated by blinking radial line. Place receiver into measurement position and press to take readings for current position. When readings for all position will be taken bore center displacement will be calculated.

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Use to select next next position or to return to the previous position. Plane number changed automatically in regard to measurement mode

Evaluate result When all bore planes are calculated, press Press

– result will display

to switch between table or H, V plot. Move bore # you are going to adjust into first line by arrow key. Then press to go “live mode”

Press

to start enter reference points number, enter numbers for both points

confirmed by

Live adjustment Press

to go to “live” adjustment mode.

When in bore position adjustment mode (“live mode”) receiver pin should be in vertical (6h o‟clock) position: 1) Fix receiver on adjusted bore – check receiver position (relative to laser transmitter beam) by receiver data on screen. Common – beam should be close to center of receiver‟s window. KOHTECT(c) 2013

Sensor live data

Calculated bore center displacement before adjustment

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2) When sensor is fixed in order to move together with adjusted bore – press position data.

to enable live bore

Live bore center displacement during adjustment

Adjust bore position to minimize displacement from common centerline, when adjustment is finished – press result update prompt will appear: Press

and stored

to save changes in bore position.

Save result Press

to enter data save screen and press

again to save soft foot reading or press

to make new directory or select the existing directory to save. .

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4.7 Flatness Program This program for measurement of plane flatness relative to reference plane formed by laser beam. The measurement points may be in the plane of circular or rectangular shape with regular or variable grid step. The plane may contain cutouts. Up to 1600 measurement points can be handled. The measurement values can be treated as absolute, recalculated to best fit plane or three points can be set as reference plane. Procedure: Plan the measurement and mark the points where the detector will be placed. Level the laser within 0.5 mm [20 mils] in both X- and Y-direction. Start the Flatness program. Use S or M unit as detector. The detector unit should be installed with the label on top.

Start Flatness program – move cursor and press

Choose option to resume interrupted work – press . In this case interrupted work will be opened for further data collecting, editing, evaluating, saving on the flash drive. To start new task – press

.

Select grid shape When new task started – the menu screen to choose plane shape appeared. Press

for taking measurements on rectangular grid

Press

for taking measurements on circular grid

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Setup grid parameters Menu screen for setting up the grid parameters: Press to set grid step – regular or variable Points across X – 2…40 Points across Y – 2…40 Grid size across X (for regular grid step) Grid size across Y (for regular grid step)

-

To set these parameters move blinking cursor by arrow keys then press

, enter the value, confirm by

.

In case of irregular grid step (“Grid Var” option): distances from first column to every next column across X can be settled individually – press to access menu distances from first row to every next row across Y can be settled individually – press

to access menu

To set distances across X – choose column by arrow keys press

then

, enter the value, confirm by

.

To set distances across Y – choose row by arrow keys

then press

, enter the value, confirm by

.

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Measured plane can contain some cutouts of arbitrary shape – those nodes that are within cutouts can be just skipped out during taking of measurement. The flatness program correctly treats such cutouts. Row and column index numbering starts from 0. E.g. first row is Y0.

Select data source When in grid setup use

to switch between data from M Unit and manually entered data.

Taking measurements Active node

Beam X position indicator

Place detector unit mounted on magnetic stand in the node of measured plane. Center the laser beam of rotation laser transmitter AVV-RL20 using the fine adjust knob on the center of detector window. Use live X, Y data on the display for beam centering.

Beam Y data Detector inclination and temperature

The AVV-RL20 laser must not be moved after measurement has commenced. First node(indexed [1;1]) is in the left bottom corner by convention. The order of taking data for nodes is not important. Assigned node is indicated on the screen by blinking cursor. Use arrow keys or alternative arrow keys move cursor on the node where detector is placed at.

to Node data recorded

Press to record node data. Repeat for each node in the plane. Nodes within cutouts can be skipped. The display cursor assigns which node in the plane to place the detector at.

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Node data not recorded yet or node is skipped

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The result display When data recorded: press

to shift to result display.

use arrow keys and review node data. Hold

or

to move cursor

to view plane data and key legend.

Sequentially press then - to setup tolerance value. Available plane data – max, min node value, spread, average, SD – standard deviation. Press to switch between node data representation - ±, all positive and all negative. Press to switch between plane data representation – absolute, best fit, 3 points reference plane.

BF – best fit ABS – absolute REF – 3 ref. points

Assigning 3 points of reference plane: -

press

to choose “REF” option.

- press to switch reference point number (order of switching – point #1, #2, #3, quit menu) - to assign – move cursor to node that will be assigned as reference and press repeat for points #1, #2, #3.

,

Three of the measurement nodes can be selected as reference points, which will set them to zero. The measurement value of the rest of the nodes will then be recalculated. Reference points can be re-assigned as required.

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Circle shaped plane Start Flatness program – move cursor and press Choose option to resume interrupted work – press . In this case interrupted work will be opened for further data collecting, editing, evaluating, saving on the flash drive. To start new task – press

.

When new task started – the menu screen to choose plane shape appeared. Press

for setting up circular grid

Setup circular grid parameters -

number of rings – press

, enter number of circles (1 to

10), confirm by -

number of points – press

, enter number of points (3 to

40), confirm by -

diameters of circles - use arrow keys circle, press

to select

, enter diameter, confirm by

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Taking measurements

Active node

Beam X position indicator

Place detector unit mounted on magnetic stand in the node of measured plane. Center the laser beam of rotation laser transmitter AVV-RL20 using the fine adjust knob on the center of detector window. Use live X, Y data on the display for beam centering.

Beam Y data

Detector inclination and temperature

The AVV-RL20 laser must not be moved after measurement has commenced. First node(indexed [1;1]) is on the top of outer circle by convention. The order of taking data for nodes is not important. Assigned node is indicated on the screen by blinking cursor. Use arrow keys

Node data recorded

or

Node data not recorded yet or node is skipped

alternative arrow keys to move cursor on the node where detector is placed at. Press to record node data. Repeat for each node in the plane. Nodes within cutouts may be skipped. The display cursor assigns which node in the plane to place the detector at.

The result display When data recorded: press

to shift to result display.

use arrow keys review node data. Hold

or

to move cursor and

to view plane data and key legend.

Sequentially press then - to setup tolerance value. Available plane data – max, min node value, spread, average, SD – standard deviation. Press to switch between node data representation - ±, all positive, all negative. KOHTECT(c) 2013

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to switch between plane data representation – absolute, best fit, 3 points reference

Press plane.

Assigning 3 points of reference plane: -

press

BF – best fit ABS – absolute REF – 3 ref. points

to choose “REF” option.

- press to switch reference point number (order of switching – point #1, #2, #3, quit menu) - to assign – move cursor to node that will be assigned as reference and press repeat for points #1, #2, #3.

,

Three of the measurement nodes can be selected as reference points, which will set them to zero. The measurement value of the rest of the nodes will then be recalculated. Reference points can be re-assigned as required.

To save data Measured data can be saved on the flash drive: - in the result display menu press

and select an existing

folder or create a new one, then press one more time. Data saved in the file with default name created with date/time stamp. Data files can be transferred to PC software for report printing, or can be opened in the AVV for review.

Quit flatness program When quit the program: - press

to backup changes in measured data.

- press

to discard changes.

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4.8 Squareness Program This program‟s purpose is to measure perpendicularity of two surfaces. Rotating laser transmitter RL-20 can deflect laser beam precisely by 90 degree by the means of a pentaprism. These two perpendicular laser beams are used as a reference. Both the transducers S and M can be used as detector. Four readings should be taken – two on the one of the surfaces, then laser beam direction should be switched and another two readings taken on the other surface.



Run Squareness program – move cursor and press



Press

to resume an interrupted measurement or



Press

to start a new measurement

Set parameters 

Enter the distances between the 1st, 2nd and 3rd, 4th measurement positions. Use arrow keys cursor between distances, then press distance in mm confirmed by

to move and enter the

.

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

Press



Key

to set resolution to 2 or 3 decimals



Key

to turn ON/OFF data filter



Key

to set the tolerance value



Key

to go to “My document” menu

to call popup menu where:

Turn ON the data filter in noisy environment conditions – such as severe vibration, or when laser beam passes through air with thermal gradients. Such conditions lead to unstable readings. Data filter improves the stability of readings. 

Use

key to change number of data blocks (between 2

and 128) used to average the readings. Take into account that greater value means slower response - more time needed to update readings.

Taking measurements 

Place detector in the 1st position. Press

to record the

reading 

Place detector in the 2nd position. Press reading

to record the Blinking cursor indicates active measurement position. Here – 1st position

RL-20 Laser beam direction for 1st and 2nd measurement positions

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

Place detector in the 3rd position. Press

to record the

reading 

Place detector in the 4th position. Press

to record the

reading

The AVV-RL20 laser must not be moved after measurement has commenced. Switch laser beam direction carefully! The order of taking data is not important. Use arrow keys

RL-20 Laser beam direction for 3rd and 4th measurement positions

to choose active

measurement position.

Measurement result When readings for all four positions are recorded, press

key to

go to the result display. If calculated tilt is out of tolerance value –second surface tilt is displayed graphically.

To save data Measured data can be saved on the flash drive: in the result display menu press create a new one, then press

and select an existing folder or one more time.

Data saved in the file with default name created with date/time stamp.

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Data files can be transferred to PC software for report printing, or can be opened in the AVV for review.

Quit squareness program When quitting the program: - press

to backup changes in measured data.

- press

to discard changes.

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4.9 Straightness Program

Press „

to resume saved task, or press

to start new task.

Straightness measurement The laser alignment system use visible laser beam to measure the straightness of linear objects. The laser transmitter (transducer that emits laser beam) is mounted at one end of the object and then aimed in the receiver. Both the transmitter and the receiver are adjusted to ensure receiver detects the laser. The receiver is moved along the object, and any changes of the laser beam position in the receiver gives a measure of straightness. The laser beam is not intended to be the absolute reference. The setup should be such that the laser beam always strikes the detector throughout the entire length being measured.

Setup parameters The setup parameters screen is the main screen of straightness program. Splice number You should define overlap points quantity when splice number >1(2 or more)

Set measurement points number To set measurement points number press „1‟ and enter desired value.

Set dimensions To set dimensions press

to select between all distances equal or different distances for

each segment. Then sequentially define distances use arrow keys

to move to next or

previous distance, press and enter desired value confirmed by . Note: when all distances equal selected system automatically set all distances to entered value, so enter distance only once. After all distances defined splice concept(see splice concept) should be followed if splice usage planned. KOHTECT(c) 2013

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Define a splice When splices planned to be used the splice should be defined. Press number(the first splice is number 1). Else leave splice „none‟.

and then enter splice

Switch between manual data and data from detector Press

to switch between manual entered data and data collected from detector

Laser beam adjustment principle Before measurement can begin the laser must be positioned such that the beam strikes the approximate center of the receiver‟s detector over the entire measurement path(whole splice or whole object).

Adjustment procedure Place the receiver at the closest(to transmitter) measurement position. Adjust beam position to center the beam onto the detector. With the receiver at the far end of the measurement path, adjust the horizontal and vertical angle of the beam to center onto the detector. Repeat above steps as necessary until the beam remains centered on the detector in both the near and far positions.

Carrying measurements To switch to data collect screen press Place the receiver at the closest measurement position for object(or splice) Use

(if necessary) to select the corresponding point number. Point

number

Splice number. if no splices then 0

In splice point index If showed means overlap point Shows stored values when not in live move mode, when in live move mode shows difference between desired and real object position

Shows actual values from the transducer

Shows actual tilt from the transducer

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Evaluate measurement results To enter to results screen when you stands in data collect screen press Measurement results screen appears When reference points not selected and best fit mode not choose measurement results is the plane stored values

Reference points. „-„ means not defined Press „4‟ to enter the reference points, press „6‟ to switch to the best fit mode

To select reference points press

and then enter points numbers sequentially

(set value and confirm by for each of points) . Note: overlap point should not be selected as reference! To deselect reference points enter 255 value for both points To switch between reference points/best fit plane mode press When reference points is selected or best fit mode is a choice measurement results is the difference between „ideal‟ straight line(desired values) and the real object position „- -„ means overlap point(appears if splices defined) this point and its distance is excluded from the results calculations The choice is the best fit mode Press mode

to change

Splice concept Splices in straightness are partial overlapped parts of whole length of measured object. Measurement divides by splices for the extension of the total length that can be measured, where object length exceeds maximum allowed distance between transducers.

To start new task with splices Press Enter number of points and then define first splice(enter number 1 for „Splice‟); You should do it before starting measurement

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After you store measurements for all the points belonging to the current splice, you can switch to the next splice. To do it: while first point of next splice selected press to return to the straightness main screen and increase splice number by one. If splice number is not 1 you should define number of overlapped points too. Number of overlapped points should not be less than 2. To input overlapped points number press then enter value, confirm by You should sequentially increase splice numbers, gaps between numbers not allowed. NOTE: distance between overlapping points must be equal to distances between points that overlaps see overlapping example below table s.1 Overlapping example Overlapping example by Transmit- 1 table(2 overlapping points, ter‟s first overlapped segment position designated by yellow back color) Absolute point number Relative to splice point number X 1. in format splice.point 1 Distances

2

3

4

1. 2

1. 1. 3 4 Splice 1 1- 2- 32 3 4 X

5

6

7

8

9

1. 5

2. 1

45

56

2. 2. 2. 2 3 4 Splice 2 7- 88 9

For Next splice transmitter‟s position(transmitter should be moved to here) Distances equality rule: 5-6 equal to 3-4, 7-8 equal to 4-5

Step by step instruction to start measure new splice Enter to collect data screen. Use for select(if required) the first point of new splice(in example this is a point 6). Move receiver to it‟s position(regards to currently selected point; in example this is a point 6, note its distance on object is equal to point 4 distance). Remember X,Y values, let me label them as “V6”). Move transmitter from its current position to position, where point of last splice point minus overlapped points number minus 1 located. In example this is a place of point 3. Do not touch receiver! Adjust transmitter so that X,Y values on receiver became almost equal to the X,Y values indicated before the transmitter has been moved. Move receiver to the closest overlapped point to the transmitter point(exact position) (in example this is a point 6, note its distance on object is equal to point 4 distance). Fine tune transmitter‟s position, so that receiver‟s X,Y values became almost equal to receiver‟s X,Y values that we previously labeled as “V6”. Repeat adjustment procedure if needed. Move receiver to the closest overlapped point at the exactly point position (in example point 6, note its physical place on object is equal to point 4 physical place, but point number 6 should be selected on the screen). Store measurement data. Then move receiver to the next overlapped point at the exactly point position (in example point 7, note its distance on object is equal to point 5 distance, but point number 7 should be selected on the screen). Store measurement data. Repeat measurements for the all overlapped points. Then continuously KOHTECT(c) 2013

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perform measurements for non-overlapped points of the current splice (in example there are points 8-9). About to how close should be values for the overlapped point pairs. In example there are two point pairs 4-6 and 5-7, so how close should be X and Y values within the pair. The answer is: as close as possible, but complete equality does not required. AVV-701 system will automatically calculate and apply correction values for each splice, but care should be taken on values difference, because if difference too big the beam can move out of the target during measurement.

The Live move mode After all measurements has been carried and results calculated, it may be necessary to make corrections in the “live” move mode. The device‟s live mode make it possible to monitor these corrections. Before switch to the live mode reference points or best fit result mode should be selected. If you move transmitter from it‟s last position, two point adjustment procedure should be performed(see adjustment procedure). Place receiver at point where you intend to make corrections. Press

to enter live mode.

String “LIVE STOP” appears at screen‟s top right side. When you ready to move press to enable live move detection. The “LIVE LIVE” start blinking at top right side of screen. The V and H values at screen‟s center now shows difference between desired and real object positions. Move object toward zero of each of these values. To stop live correction press again “LIVE STOP” appears at screen‟s top right side. Live move mode is ON

To save data Measured data can be saved on the flash drive: in the result screen press

and select an existing folder or create

a new one, then press one more time or press new directory or select the existing directory to save. KOHTECT(c) 2013

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Data saved in the file with default name created with date/time stamp.

4.10 Cardan program Cardan Shafts, or offset mounted machines, need to be aligned just as much as an ordinary mounted machines. The cardan shaft with its ball-joints admits an amount of offset mounting of the machines, but it does not tolerate angular misalignment. To be able to perform an alignment of an offset mounted machine you will need to use the optional brackets. See also horizontal machine alignment.

Two machines joined via a cardan spacer shaft Flange Movable machine Bracket rail

Swivel bracket 1. To compensate offset, mount the bracket rail on the shaft end of the stationary machine. 2. Mount the swivel bracket on the bracket rail. Mount S transducer on the swivel bracket 3. Mount the magnet fixture on the end of the shaft of the movable machine. Mount M transducer on the fixture. 4. Connect the S- and M- transducer to the display unit and start the Cardan program to switch on the lasers.

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5. Adjust the M transducer beam.

To adjust the laser beam: Turn the transducer into first position – e.g. 9 o’clock. Note the beam position on the opposite transducer (e.g. beam hits position 1). Turn the unit half a turn (beam hits position 2). Adjust the beam to the centre of rotation (beam hits position 3 in the middle between point 1 and 2).

6. Adjust the brackets rail so the center of the S transducer is hit by the M transducer‟ laser. 7. Adjust the S transducer beam. Adjust the bracket rail

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To start program press

Press „

to resume saved task, or press

to start new task.

Input dimensions As offset value is not used in cardan shafts only distance between transducers and distance between front and rear feet of machine need to be entered Use data.

or

to move from dimension to dimension to input or reconfirm all dimension

To start input dimension use key, when the blinking cursor appeared use numeric key pad to enter desired value then press

to confirm.

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Collect data Collect data for the cardan shaft shares many similarities with horizontal machine alignment, see collect data. To start collect data press The laser beams turned on now. Screen of wait connection to transducers appears. Note that Bluetooth connection need more time for connection to be established. If connection cannot be established during more than 90 seconds check if pin codes entered or check transducers.

Transducers serial numbers become available when connection established

After the connection has been established data collect screen appears. Face the stationary machine from the movable machine. Blinking outer circle means minimum turn violation Use to store point Up to 36 points can be stored, minimum 3 points should be stored Minimum turn requirements should be respected(>10°) NOTE: to achieve acceptable results the whole shafts turn must not be less than 120 degrees. Stored point can be edited, or deleted, refer to horizontal alignment view and edit the points

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Calculate alignment results When all of the desired points gathered press to go to view calculated results and to make live adjustment Note: Screen message shows “Do not turn shafts” The alignment measurement result of calculations shows the values of the angular “Gap” misalignment in the plane of the coupling (in Horizontal and Vertical planes) as well as the correction values for the machine feet F1 (machine front feet) & F2 (machine rear feet) on the movable (M) machine that are necessary for eliminate the horizontal and vertical angular misalignment. Sequentially press and to change tolerances, see also horizontal alignment setup tolerances

To start corrections for the misalignment To correct the horizontal and vertical plane in biaxial as per obtained coupling result in, press to switch frozen result screen to “LIVE” mode with shaft remain at last recording clock position. Blinking “LIVE” at the top right of the screen indicates live adjustment mode is on Refer to horizontal alignment section corrections of the misalignment Note that offset not used for the cardan shafts alignment Use

to switch between live and frozen mode

To save data When measurement finish, press

to enter file save display. Press

again to save the alignment result main directory or new directory or select the existing directory to save.

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Quit cardan program When quitting the program: - press

to backup changes in measured data.

- press

to discard changes.

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4.11 Spindle program For spindle alignment S unit(transmitter) mounted in the spindle and the M unit(detector) mounted at the part of the machine that can be moved along the working area of the machine. To start program press

Input distances Press to start input distance between first and second detector position, use numeric keypad for entering value, confirm by

Taking measurement When distance entered press

to go to tacking measurement

After the connection established measure points can be stored

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S unit inclinometer data

Black shows S Unit label position

M unit placed in first position now M unit values 1 Place detector(M Unit) at the first position 1.1 Turn spindle so that the label of the S Unit positioned on top Press to store point 1.2 Turn spindle so that the label of the S Unit positioned on bottom(rotate it 180º) Press to store point 2 Move detector to the second position 2.1 Leave spindle in position so that the label of the S Unit positioned on bottom Press to store point 2.2 Turn spindle so that the label of the S Unit positioned on top(rotate it 180º) Press Use

to store point to walk through measurement position if need

Evaluate results After all measurements stored result screen appears Angular error showed numerically and graphically Use

to go to remeasure positions if any

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To save data When measurement finish, press

to enter file save display.

Press again to save the alignment result main directory or to make new directory or select the existing directory to save.

To quit program press

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5.0 Standards Tolerance of Shaft Misalignment This chapter provides the standards alignment tolerance of misalignment for standard industrial machinery with flexible coupling that can be used under condition only if existing in-house standards or the machine or coupling OEM have not given any blinding values, and must not be exceeded.

Speed, rpm Up to 1000 Up to 2000 Up to 3000 Up to 4000 More than 4000

Offset 0,08 0,06 0,04 0,03 0,02

Good Angular (Gap) 0,07 0,05 0,04 0,03 0,02

Offset 0,12 0,10 0,07 0,05 0,04

Acceptable Angular (Gap) 0,10 0,08 0,07 0,05 0,04

6.0 Delivery Set № 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Description Control Display Unit Measuring Transducer Unit Brackets Fame Chains assembly Supporting Rods Connecting Cable AC Charger, 220-230Volts Tape Measure 2m Carrying Case Operating Instructions Manual CD-ROM Software USB PC Communication Cable

Qty 1 2 2 2 4 2 1 1 1 1 1 1

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