1

SYSTEM 2
Maintenance Work Station

Computer Operating Instructions

Dear Customer, This manual is contains instructions for the SYSTEM 2 computer, case and accessories. Instructions for the use of the individual application programs such as TURBALIGN, CENTRALIGN etc. are given in their own separately supplied software operating instructions. If you have any suggestions for improvement or corrections (not just for this manual, but also for software or hardware), please give us a call or drop us a line! We would be glad to make improvements wherever possible. We look forward to hearing from you!

Edition September 1995 SYS 9.514 G

PRFTECHNIK AG Documentation Department Fax (+49) 89 / 99 61 62 00

2 Foreword

Foreword
Congratulations! And thank you for choosing the world's most advanced maintenance system! As rotating machinery maintenance changes to meet the demands of modern industry, predictive maintenance trends continue unabated toward reducing routine legwork by raising standards to provide a wide variety of timely, accurate information. Modern operating methods already commonplace in other areas are now finding their way into inspection, repair and service as a costeffective means of raising productivity and machine availability while reducing the incidence and associated costs of repairs. SYSTEM 2 is made for maintenance: ordinary computers intended for office use cannot cope with hostile industrial environments, but with SYSTEM 2, maintenance personnel at last have a computer to call their own. Custom-designed and made in Germany, all components are produced to take in stride the rigors of daily maintenance rounds. SYSTEM 2 is made to go anywhere: its custom-made case opens into a mobile work station at the job site, with all operating elements ergonomically situated in a convenient working position. SYSTEM 2 is versatile: a wide range of programs designed for specific maintenance applications lets you measure and document alignment of shafts and bearing pockets, vibration analysis, rotor balancing, straightness measurement, and a host of other position-related measurement tasks using interchangeable sensors coupled with the same easy-to-use operating controls - a sure cure for computerphobia! Simply plug in different program cards and sensors to transform the very same SYSTEM 2 computer from, say, a turbine train alignment computer into an FFT vibration analyzer in just a few seconds. SYSTEM 2 computer features are designed with the special needs of the service and maintenance specialist in mind: a large, legible display with clear graphics, an easy-to-use, rugged keyboard, a built-in printer for documentation of results, abundant easy-access memory, a wide range of truly useful application programs and capability to connect with many different measurement systems and sensors In the years to come, further innovations in sensor technology and supporting software will be introduced to uphold the leading edge of SYSTEM 2 in measurement, control and data storage technology for the maintenance professional. Please contact your local Prftechnik representative periodically to learn about the latest applications available for your work station. We wish you much success and enjoyment with this revolutionary new measurement concept! Ismaning, September 1995 PRFTECHNIK AG

3 Contents

Contents
Foreword .......................................................................................... 3 At a glance ....................................................................................... 4 Warranty, service and care ............................................................. 6 Getting started ................................................................................. 7 Preparing for operation ............................................................. 7 After use ..................................................................................... 9 The collapsible cart (optional) ................................................ 11 The SYSTEM 2 Traveller case ................................................ 12 SYSTEM 2 Lite ........................................................................ 13 The SYSTEM 2 computer .............................................................. 14 General description .................................................................. 14 Data cards ................................................................................ 15 Formatting data cards .............................................................. 18 Interfaces .................................................................................. 19 Hardware module .................................................................... 20 Replacing printer paper roll and ribbon ................................. 21 Battery charging ....................................................................... 22 The computer carrying strap ................................................... 24 The transparent computer cover ............................................. 26 Computer operation, step by step ................................................. 27 SYSTEM 2 Computer software overview ................................. 28 Switching on the computer ..................................................... 29 The measurement data file ...................................................... 31 The program information display ............................................ 33 The configuration display ........................................................ 34 The system display ................................................................... 35 Clock ......................................................................................... 36 SYS2Commander installation instructions .................................... 37 Troubleshooting checklist .............................................................. 38 SYSTEM 2 Application programs ................................................... 40 Technical data ................................................................................ 41 SYS2Commander operating instructions ....................................... 43 Index .............................................................................................. 46 Software license agreement .......................................................... 47
Notice With any data processing software, data may be lost or altered under certain circumstances. PRFTECHNIK AG strongly recommends that you keep separate written records of all important data. PRFTECHNIK AG assumes no responsibility for data lost or altered as a result of improper use, repairs, defects, battery replacement/failures or any other cause. PRFTECHNIK AG assumes no responsibility, directly or indirectly, for financial losses or claims from third parties resulting from the use of this product and any of its functions, such as loss or alteration of stored data, etc.

4 At a glance

At a glance The SYSTEM 2 computer

Additional connections RS-232C interface for communication with PC's or external printers EGA interface for connection of an external monitor Sensor interface Connects measurement components such as the TURBALIGN infrared turret or vibration probe/ trigger cables for VIBROSPECT FFT

Printer

Program cards Memory cards

ON/OFF key Printer key Press and release to advance paper. Press and hold (>1 sec) to print screen contents. Press again during printout to stop printing.

PRUFTE

CHNIK AG

Power supply Built-in rechargeable battery (6 V, 2 Ah). Main case battery (12 V, 9 Ah); AC supply via case charging jack.

Contrast adjustment Continuously adjustable contrast adapts the screen to all ambient lighting conditions.

LCD screen 224 x 122 mm 640 x 350 pixels With fluorescent backlighting (also available without backlighting) and adjustable contrast

Keyboard 34 variable function keys (Softkeys), The program continuously controls which keys may be pressed, according to the situation at hand.

Help key Displays explanatory text for the current screen.

5 At a glance

The SYSTEM 2 case

External charger connection jack

Computer raised into working position

Compartment 1 Provides storage for emitter, receiver, sensor batteries, deflection mirror, shades, various vibration probes for use with FFT, tape measure, external batteries, program/memory cards and magnetic brackets. Inside (not shown): Charging rail Charges 10 sensor batteries simultaneously Battery charger Charges main case battery and computer battery

Not shown: Main case battery (12 V, 9 Ah) in bottom of case

Compartment 2 provides storage for the belt-type bracket pouch, computer carrying strap, and vibration probe cables.

6 Warranty, service and care

Warranty, service and care

The SYSTEM 2 is a precision measurement instrument and as such deserves the proper care in handling. The case is extremely versatile, as it provides a convenient work station when opened as well as orderly storage and transport protection when closed.

The SYSTEM 2 computer housing may be opened for servicing only by PRFTECHNIK or its authorized customer service representatives. Any unauthorized service attempt will invalidate the warranty and may result in costly additional damage.

Warranty
Warranty coverage of one year is provided on parts and labor.

Service and care

SYSTEM 2 requires no maintenance! Please do observe the following points, however: The accuracy of the measurement sensors should be checked every 2 years. The next inspection date can be seen on the colored label located on the back of the sensor housing as shown at left. At that time, please return the entire measurement system to PRFTECHNIK AG for calibration checking. The optical surfaces of sensors may be cleaned using a soft artist's brush or the ALI 2.905 cleaning set. The computer case may be cleaned using a soft cloth dampened with a mild detergent solution. The SYSTEM 2 case is key lockable. Be sure to remove the key before transporting the case so that it cannot break off. The fourdigit key identification number may be recorded in the boxes at left to make for easier replacement in case of loss or damage.

Enter your case key number here

Battery life
Computer: With active backlit display approx. 7.5 hrs. (18 hrs. with nonlit passive display) when main case battery is used; 1 hr. (3.5 hrs. passive) when built-in computer battery is used alone. Charging duration: Case & computer batteries approx. 5 hrs.

Temperature range
The recommended range of operating temperature for TURBALIGN is 0 to 45 C (32 to 113 F) or, for computers with unlit displays, 0 to 50 C (32 to 122 F); the system may be stored at temperatures between -25 and 60 C (-13 to 140 F) or, for computers with unlit displays, -20 to 60 C (-4 to 140 F). Under no circumstances should the computer be exposed to direct sunlight for any length of time, as that would cause it to become overheated. Operating Computer with passive (unlit) display Computer with active (backlit) display 0-50 C 32-122 F 0-45 C 32-113 F Storage -20-60 C -4-140 F -25-60 C -13-140 F

7 Getting started

Getting started: preparing for operation

Open the case by unfastening both side latches (1), then flipping the front of the case up into working position as shown (2). Grasp the computer below the screen and rotate it upwards out of the case lid until it locks into working position (3).

3 2

The computer may now be completely removed from its case by loosening the large locking screw from its underside, then lifting it upwards.

The computer carrying strap (optional, SYS 2.070) may now be attached by inserting its end hooks into the slots located on the underside of the computer housing.

8 Getting started

The sensors are contained in the rear wall of the case (1), while the charger/AC power supply and brackets are stored in the bottom (2). Remove them by pulling open the lower case panels as shown below.

The individual components of most standard SYSTEM 2 applications fit into the contoured foam case insert. Extra slots are provided for additional accessories such as magnetic brackets, vibration probes or program/memory cards.

9 Getting started

After use
When finished, make sure the locking screw on the underside of the computer is tightened to hold it into the case.

Then release the case locking mechanism by pressing both blue side buttons inwards (1) and gently lowering the computer back into its original storage position in the lid of the case (2).

10 Getting started

Press the purple button located on the inside of the hinge (1) to release the locking mechanism while gently closing the lid (2), then refasten both black side latches (3). The case may also be locked for extra security. (Be sure to remove the key after locking to prevent accidental breakage.)

3 3

11 The collapsible cart

The collapsible cart

(optional, SYS 8.801)

The optional cart makes for easy transportation of the SYSTEM 2 case from one machine site to the next during routine measurement rounds. Especially when your system is fully-equipped with auxiliary measurement programs and accessories, this cart provides a welcome extra measure of convenience. Open the cart as shown below:

Be sure to tighten the strap around the case below the lock as shown below, so that the case can be opened for working without having to remove it from the cart. Fasten the case handle to the cart frame with the strap provided.

N N I G F L IG I P F A L L N O B A A T R T V IG L N C U P O A IG E T O N P M LS N N N R A G G E V O I IG I P O R L L L N IB A A A V M V M R O R N E P

TE SYS

M2

12 The SYSTEM 2 Traveller case

The SYSTEM 2 Traveller case

As an alternative to the standard work station case just described, SYSTEM 2 can also be supplied upon request in a robust 'Traveller' flight case configuration. Conceived especially for the maintenance specialist on the go, the Traveller case is dust- and water-resistant and rugged to withstand air-plane travel. The case includes a 5.7 Ah rechargeable battery for up to 10 hours of continuous operation.
Case 2 Case 1

Charger Sensor battery charging rail

Printer

Memory card, 256 kB Main battery beneath computer Hardware module

Battery operating duration: With 'active' backlit display With 'passive' non-lit LCD display

6h 10 h

13 SYSTEM 2 Lite

SYSTEM 2 Lite
This package contains components common for shaft alignment and vibration analysis (including rotor balancing and machine diagnosis) in a lightweight, compact case. To save weight, it does not include the main battery contained in the SYSTEM 2 work station case. The display is unlit to attain maximum operating duration from the builtin computer battery.

Charger

Printer

Memory card, 256 kB

Hardware module

Battery operating duration: With 'active' backlit display With 'passive' non-lit LCD display

1.5 h 4h

14 The SYSTEM 2 computer

The

SYSTEM 2

computer

The SYSTEM 2 computer is designed to withstand the rigors of dayto-day operation in severe industrial environments, so it requires no special attention besides occasionally wiping the case with a soft cloth (if necessary, dampened slightly with a mild detergent solution).
NOTE: The SYSTEM 2 computer may be serviced only by PRFTECHNIK or its authorized service centers. Any unqualified service attempts will void the warranty and may cause further damage, requiring extensive repair effort to rectify.

Printer Program/ memory cards

Keyboard

Hardware module

PRUFTE

CHNIK AG

Screen

The illustration above shows all major components of the computer. Note that once the proper hardware module and program and memory cards have been installed, all operations are controlled from the keyboard arranged around the display screen.

The computer display

The SYSTEM 2 computer display is available with or without cold fluorescent backlighting, depending upon the lighting conditions under which it is to be used: in brightly-lit surroundings such as outdoors, the non-lit 'passive' display provides excellent contrast for easy reading. For indoor use, especially in poorly-illuminated surroundings, the backlit display is most legible.

15 The SYSTEM 2 computer

Data cards
The software used to run SYSTEM 2 applications such as TURBALIGN or VIBROSPECT FFT is programmed onto easily-interchangeable cards, and measurement data are stored onto the same type of card so that measurements from each particular machine aggregate can be recorded on its own card over time. The program cards are available in two different versions: the 'master' card is capable of running all by itself, while the 'slave' version of the same program can run only in conjunction with any master card. Memory cards are available in three different sizes: 64 kB, 256 kB or 1 MB. Their basic function is to store measurement data, just as you would record alignment corrections or vibration readings on a recording log sheet. Since the measurement data files for all SYSTEM 2 programs use the same format, measurements taken with different programs may be stored on the same data card. Each program loads only its own measurement files. The RAM cards may be distinguished from one another by removing them to consult the label affixed to one side.
Under no circumstances may a program card (or the VIBROSPECT FFT data card) be removed while the computer is switched on!

Program and memory cards are interchanged by grasping at the sides with thumb and forefinger as shown above, then carefully pulling straight up (not rocking back and forth). The new card then simply plugs into place. Any unoccupied card slots should be kept covered using SYS 2.050 inserts.

16 The SYSTEM 2 computer

Each of the four card slots has its own particular function, so be careful to install each card only in its proper slot: Slot 1: 'Master' program card, controls program execution (for example, TURBALIGN) Slot 2: 'Slave' program card, for execution only with a master in slot 1 (for example, VIBROSPECT FFT - or use this slot to 'park' a second master) Slot 3: Measurement data memory (64kB size is standard equipment with OPTALIGN/TURBALIGN 1.5; VIBROSPECT FFT uses 256 kB), or source card for measurement data backup Slot 4: May be used only for the destination card during measurement data backup or for 'parking' extra cards. The illustrations below and on the following page show examples of proper card installation for a variety of SYSTEM 2 application situations.

Minimum configuration for VIBROSPECT FFT Master ( no card ) program Memory ( 256 kB ) ( no card )

VIBROSPECT

FFT

1 2 3 4

2 programs (TURBALIGN master & VIBROSPECT FFT slave ) Master program Slave Memory ( 256 kB ) ( no card )

TURBALIGN

VIBROSPECT

FFT
RAM

1 2 3 4

RAM

17 The SYSTEM 2 computer

2 programs ( VIB FFT master & TURBALIGN master ) 1st master 2nd master program program (`parked`)
FFT
R

Data card

( no card )

VIBROSPECT

TURBALIGN

1 2 3 4

Measurement data backup Master program ( no card ) Source Destination card card

TURBALIGN

RAM

RAM
RAM

1 2 3 4

The lithium battery built into each measurement data card provides power sufficient to maintain data for (typically) 6 years from the date of manufacture; do not store the card at temperatures exceeding 25 C (77 F) or else the battery life may be considerably shortened (see below). Toward the end of this 6-year battery life, make a backup copy of the stored data onto a new card, then return the old card to Prftechnik for battery replacement: ask your Prftechnik representative about our low-price memory card replacement program. Temperature Shelf life 25 C (77 F) 6 years 50 C (92 F) 1.5 years

Store all program and memory (RAM) cards in a cool place!

Do not store RAM cards above 25 C (77 F)!

Note: improper handling can lead to RAM card data loss! Prftechnik assumes no responsibility for lost data under any circumstances.

18 The SYSTEM 2 computer

Formatting data cards

When a new data card is to be put into service, it must first be formatted for use with the proper program before it can record measurement data. This requires use of a master card of any program, which must be inserted in slot 1. The card to be formatted must be located in slot 3.

Formatting a memory card Master Card to be program formatted

TURBALILGN

1 2 3 4

Turn on the computer and, if necessary, select the 'master' program in slot 1 to reach the title display. Then press the key marked 'Format' in the lower right corner of the display.

The computer requests confirmation before it erases the card in slot 3, indicating the presence of any old files which will be lost. Once 'OK' is pressed, the card is immediately ready for use with any SYSTEM 2 program.

RAM

19 The SYSTEM 2 computer

Interfaces

Vibration probe sockets shaft alignment transducer/ optical trigger sensor socket

EGA graphics interface Charger socket

RS232-C interface

The SYSTEM 2 computer is equipped with a RS-232C interface for easy data transfer with other computers and serial printers. The EGA graphics interface allows simple connection of an external display screen. The charts below tell the pin configurations for the trigger and both interfaces as seen on the rear side of the computer. Use the RS232C chart to ensure proper printer cable connections. Interface configuration parameters may be changed in a menu obtained by pressing the key marked Config when the computer is first switched on.

Note: This particular RS-232C configuration should NOT be used with a serial/parallel converter. Some converters and parallel printers expect a different configuration and could be damaged.

5 9

4 8

3 7

2 6

EGA

Pin Pin Pin Pin Pin Pin Pin Pin Pin Pin Pin Pin Pin Pin Pin Pin Pin Pin

1: 2: 3: 4: 5: 6: 7: 8: 9: 1: 2: 3: 4: 5: 6: 7: 8: 9:

Ground Ground Video (red) Video (green) Video (blue) Intensity Video Horizontal sync Vertical sync do not Rx D TxD do not GND do not RTS CTS do not use

internally linked internally linked (monochrome output)

1 6

2 7

3 8

4 9

use use

Trigger (linked together in plug) Ground Trigger

RS-232C

use

20 The SYSTEM 2 computer

Hardware
The hardware module should be replaced only by a qualified electronic service technician; otherwise, the module and computer may easily become damaged, invalidating all warranty coverage.

module

The sensor interface, or 'hardware module,' built into the SYSTEM 2 computer is available in various configurations to suit any combination of user requirements. Its modular design allows replacement to allow upgrading later as the system expands and other measurement tasks are added.
OPTALIGN 1.5 or TURBALIGN 1.5, with VIBROSPECT FFT SYS 2.252

PERMALIGN and VIBROSPECT FFT

SYS 2.262

VIBROSPECT FFT alone

SYS 2.292

TURBALIGN (infrared turret), TURBALIGN, CENTRALIGN, VIBROSPECT and NOVALIGN SFFT (infrared PERMALIGN, installed turret), VIBROSPECT FFT and PERMALIGN

SYS 2.242

21 The SYSTEM 2 computer

Replacing printer paper roll and ribbon

4 3 5 1 2

To replace the paper roll, first remove the computer from its work station pedestal (loosen the large knob on the underside if necessary). Then flip open the printer compartment cover as shown (1). Remove the old roll and from it remove the roll spindle. Insert the spindle into the new roll (order no. ALI 2.910). Install the roll in the orientation shown (also referring to the pictograms on the inside of the printer compartment cover), and thread the paper through the printing mechanism (2). Switch on the computer and press the hard copy key to feed approximately 10 cm (4") of paper through the printer so that it can easily be threaded through the slot in the cover. (If the printer does not react, switch the computer off and then back on; enter the 'Config.' menu and change the printer setting to 'internal.') Pull the paper taut while closing the cover. Replace the computer on its work station pedestal and secure it into place using the large knob on its underside. To change the printer ribbon, remove the computer from its work station pedestal (loosen the large knob on the underside if necessary). Then flip open the printer compartment as shown (1) and pull the paper out of the printing mechanism. Locate the end of the ribbon cartridge marked EJECT/PUSH and depress it to remove the old cartridge. Before inserting the new cartridge (order no. SYS 2.051), turn its tension wheel to ensure that the ribbon is taut. Insert the tension wheel end first (3), then press the end marked PUSH (4) until the cartridge snaps into place. Turn the tension wheel again a bit to seat the ribbon properly within the printing mechanism (5). Reinsert the paper as described above.

22 The SYSTEM 2 computer

Battery charging
IMPORTANT:
To prevent overheating, remove the battery charger completely from its compartment in the bottom of the SYSTEM 2 case before use!

Main battery operating duration: With 'active' backlit computer display 10 h With 'passive' non-lit LCD computer display 18 h

The main battery, capable of powering the SYSTEM 2 computer for up to 18 hours (with unlit passive display, or 7 hours with backlit active display), is located in the bottom of the case. The computer itself contains a smaller battery to provide about 3 hours of operation (with unlit passive display, or about 1 hour with backlit active display) when the computer is detached from its work station base. One way to maximize operating time is to use the Auto-Off feature (described on page 34).
The operating voltage of the battery charger can be changed internally from 220 V to 110 V by a qualified electronic service technician.

Use only the battery charger (SYS 2.030) originally supplied with SYSTEM 2. Check to make sure that the voltage marked on the charger label matches the mains supply, then plug the charger into the mains first (its green indicator LED should glow). Now insert the round plug into the charging socket of the computer (located on its rear panel, see p. 19) or the side of the case; note the socket keyway for proper plug orientation. Note, however, that if the charging socket on the computer is used, only the computer battery will be charged. If the green indicator LED on the charger should go out when a battery is connected, the battery may be damaged and may require replacement. The reset button on the charger must then be pressed before reconnection. The charging process may be checked by switching on the computer and pressing the key marked SYSTEM: besides the percentage scale showing the level of battery charging, the current meter (marked 'A') should read a positive value during charging.

23 The SYSTEM 2 computer

The computer battery requires approximately 2 hours to charge, and about 5 hours are needed to charge both computer and main batteries at the same time. Thanks to the SYSTEM 2 intelligent power management system, the lead-acid batteries in the computer and case will not be damaged even if left charging indefinitely.

24 The computer carrying strap

The computer carrying strap

SYS 2.070

The computer carrying strap, available optionally under order number SYS 2.070, allows you to take the computer along on routine measurement rounds and to examine results directly at the machine being measured, even when working space is severely limited. Remove the strap from its compartment in the lower part of the case. The fabric strap itself is rubber-lined to prevent slipping. Attached to its ends are metal brackets with spring-loaded plunger hooks which fasten to the bottom of the computer housing.

PTB No. Ex-81/2125

8.510 VIB

Serial No.

25 The computer carrying strap

Attach the strap as follows: 1. Remove the computer from the case as previously shown by loosening the locking screw and lifting out the computer. 2. Turn the computer over so that its bottom faces upwards. 3. Place the hooks in the metal slots (1) on both sides of the housing. 4. Press the plunger so that the hook can be pulled into locking position (2).

5. Make sure that the plunger snaps back out when the hook latches into proper locking position. The strap is now securely fastened into place and can be used to carry the computer. 6. Remove the carrying strap in reverse order.

26 The transparent computer cover

The transparent computer cover

SYS 2.071

This optional accessory offers additional protection when the computer is to be operated in extremely wet or dirty surroundings. Simply slip the cover over the computer; the function and appearance of keyboard and display remain unaffected, while the heavy vinyl covering may be wiped clean with a cloth (using mild detergent if necessary).

27 Computer operation, step by step

Computer operation, step by step

The SYSTEM 2 computer is designed to be especially easy to use, even for those with no prior computer experience. The Softline system provides on-screen labels for the keys surrounding the entire display, so the user has only to select from the options available at any one time. In this manner, the program guides the user through the entire alignment procedure. The graphic flow chart on the following page gives an overview of the measurement sequence. It is intended to help the new user to locate quickly and conveniently each specific function in the alignment process.

28 Computer operation, step by step

SYSTEM 2

Computer

software

overview

SCREEN 1 APPLICATION TITLE

Information Configuration Units Date Language Printer Auto-Off RS-232C System Battery Current Temperature Contrast Contrast adjustment Clock Load file Save file Delete file Backup card Format card Rename machines New machine set Operator name NOVALIGN 'S' feature only: Report CENTRALIGN feature only: Export

29 Computer operation, step by step

Switching on the computer

Turn on the computer by pressing the key at the upper right corner of the keyboard (marked /).The SYSTEM 2 computer keyboard utilizes Softline menus to guide the user through the entire measurement program by offering a selection of keys which changes to suit the situation at hand. Instead of having printed markings on the keys, each active key is labeled at the edge of the display, with an arrow (and sometimes a line) connecting the label to the key.

If the computer is equipped with two program cards simultaneously (i.e. the 'master' version of OPTALIGN 1.5 or TURBALIGN 1.5 in slot 1, and the 'slave' version of another application in slot 2), the first screen to appear when switched on allows you to select which application should run. In the case pictured above, press any key in the top row of this display to run TURBALIGN 1.5. The resulting display is shown on the following page.

30 Computer operation, step by step

If only the OPTALIGN 1.5/TURBALIGN 1.5 program card is in place, the computer screen shows the following display when first switched on:

IMPORTANT NOTE FOR OPTALIGN 1.5/TURBALIGN 1.5 USERS: Now the computer displays the serial number of its hardware module. Check to make sure that this number matches the last digits of the serial number on the back of the transducer housing, as these components are uniquely matched and must always be used together to maintain measurement accuracy and laser safety.

This first display allows several preliminary adjustments to be made in the overall measurement configuration, as explained on the following pages. To obtain further instructions on screen at any time during the measurement program, press the Help key (marked '?') located in the lower right corner of the keyboard. When finished with this display, press the key at the upper right labeled 'Next screen' to proceed to the next display.

31 Computer operation, step by step

The measurement data file

The machine train may be renamed by pressing the 'Rename' key; pressing the 'New' key will erase all details of the current train so that a completely new set may be entered. Press the key located beneath the operator figure to enter or change the name of the person carrying out measurements. Machine dimensions and alignment measurements are stored as a set for an entire train on the computer RAM cards. To change from one previously stored train to another, press the key marked 'Load' to obtain the following file selection menu:

All shaft alignment measurement files stored on the RAM filer (data storage) card in slot 3 are now listed in the order in which they were originally saved. Each file name is followed by the date and time when it was stored. (The date and time formats may be changed using the 'Config' key.) Choose the file to be loaded by moving its name to the highlighted line with the up/down arrows. Then load the file by pressing the arrow key pointing toward the highlighted line. To cancel this operation without loading a new file, press the key marked X. The RAM filer (data storage) card can be formatted (completely erased) by pressing the corresponding key at the top of the 'Load File' menu.

32 Computer operation, step by step

The machine configuration and measurement data are stored by pressing the key marked 'Save.' Before storing the file, the computer allows you to enter a descriptive comment to be displayed briefly each time the file is loaded. Save the measurement data frequently during each job, so that the latest data cannot be lost in case they become overwritten or erased by mistake. The 'Save' function is also available after measurement when results are displayed. The key marked 'Delete' allows any set of machine data to be erased from the RAM card. Just as when loading files, choose the file to be deleted by moving its name to the highlighted line with the up/ down arrow keys, then select the file by pressing the arrow key pointing toward the highlighted line, or cancel the delete operation by pressing the menu key marked X. Before deleting the file, the computer asks you to reconfirm, giving you one last chance to cancel with the key marked X. The key marked 'Backup' copies the entire contents of the RAM card in slot 3 to the RAM card in slot 4. Before carrying out the backup, the computer asks for confirmation to avoid inadvertent data loss. If either or both cards are missing, the computer displays an error message accordingly. The 'Format' key is used to completely erase the data memory card in slot 3. See page 18 for detailed instructions on the formatting procedure.

Copying individual files

To copy an individual measurement file from one RAM memory card (the 'source' card) to another (the 'destination' card) without having to back up the entire card, simply follow these steps: 0. The second RAM memory card must be formatted before it can store the copy of the measurement file. 1. With the source card in slot 3, switch on the computer, run the program and load the desired file as directed on the previous page. You may want to make a written note of the comment that appears when the file is loaded so that you can enter it with the copied file. The file contents are now transferred into the working memory of the computer and will not be lost until another file is loaded or the program card is changed, even if the computer is turned off and on. 2. Switch off the computer, remove the source card from slot 3 and replace it with the destination card. Switch the computer back on. The desired measurement file is still loaded. 3. Press the 'Save' key, then 'OK' to store the desired file onto the destination card. You may enter a comment and file name as desired.

33 Computer operation, step by step

The program information display

Press the key marked 'Info' to produce the following display.

Following the program title is a line regarding the type of laser diode to be used: the program automatically reads this information from the particular hardware module installed in the computer. The hardware module contains data describing the particular transducer to which it is matched, so remember not to 'mix and match' transducers and computers in order to maintain accuracy and proper laser beam control. Under no circumstances may an infrared (invisible) laser transducer be attached to a computer with a visiblelaser hardware module: this would make the laser operate outside the Class I safety limits! The software and hardware version numbers identify the status of the alignment program and ensure compatibility between program and computer. Check with your Prftechnik representative from time to time on the availability of program updates.

34 Computer operation, step by step

The configuration display

Press the key marked 'Config' to produce the following display. When the keys marked 'Time' or 'Date' are pressed, the keyboard becomes numerical so that the new setting may be entered directly; all other available soft keys act to leaf through the list of available choices for that particular parameter each time the key is pressed.

Note: the settings available for some SYSTEM 2 programs may vary slightly from those described here. In that case, these are described in the separate software operating instruction manual.

Additional parameters which may be changed include the following: Language: Units: Printer: Date format: Auto off: German, English, French or another, fourth language Metric (mm) or U.S. (inches and mils) Internal or external (such as Epson FX-80) International (ddmmyy), or American (mmddyy) Enabled (for display darkening, then automatic shutoff of computer after five minutes of nonuse) or disabled Hardware module or printer port (the latter allows connection of sensors via the RS232-C interface)

Sensor port:

RS232-C parameters Baud rate: 1200, 4800, 9600 or 19200 Data format: 7- or 8-bit Parity: Even, odd or none Handshake: RTS/CTS, XON/XOFF or none To confirm the final setup, press the 'Quit' key.

35 Computer operation, step by step

The system display

Press the key marked 'System' to obtain this display, which provides information on the computers current operating conditions. The V-meter diagram shows the voltage level of the built-in rechargeable batteries. The A-meter diagram shows current consumption (as a negative meter deflection) or battery charging (as a positive deflection which will gradually decrease down to 0 as charging progresses).

The scale marked with an hourglass tells approximately what fraction of the full battery charge is left. When the charge runs into the negative range on this scale, the computer may run out of power at any time and therefore should be charged immediately (as indicated by the message proceed at your own risk!) The thermometer indicates the temperature within the computer housing, which should always be held within a range of 0 - 45 Celsius (32 - 113 Fahrenheit), or for unlit computer displays, 0 - 50 C (32 - 122 F). Under no circumstances should the computer be exposed to direct sunlight for any length of time; otherwise overheating may result. The arrow and bars below it indicate the display brightness setting, which can be adjusted anytime (even when the system screen is not active) by pressing the special key in the bottom left corner of the display. Return to the first display by pressing the key marked 'Quit.'

36 Computer operation, step by step

Clock
The current time and date can be called on screen by pressing the clock key. Press any key to remove them from the display. The time or date can be reset by pressing the 'Config.' key, then pressing the 'Time' or 'Date' key.

37 SYS2Commander installation instructions

SYS2Commander installation instructions

SYS 2.021 SYS2.020SET SYSTEM 2 Commander Update SYS2Commander Kit (software, cable, adapter)
See page 43 for complete operating instructions for SYS2Commander.

Hardware requirements
Your computer must have a 100% IBM-compatible RS-232C serial interface available in order to work properly with the SYS2Commander software. The software has been tested on the following systems: COMPAQ DESKPRO 386/25e
COMPAQ 386S20

Toshiba T 1600 Toshiba T 3100 As well as various other makes of 100% IBM-compatible PCs

Software requirements
SYSTEM 2: The SYS2Commander is supported by the following program versions: TURBALIGN 1.5 Version 2.03 and later TURBALIGN Version 2.06 and later VIBROSPECT FFT Version 2.02 and later Version 1.12 and later (with balancing) Version 1.20 and later (with balancing and diagnosis)

This program may not be used with earlier software versions than those listed above!

Computer: This software runs on PCs under MS-DOS, Version 3.xx.

Installation
Use the correct disk size for your computer's disk drive (3" or 5"). 1. Insert the disk. At the DOS prompt, enter the installation command for the drive containing the program disk:
A:INSTALL 2. Enter the DOS path of the directory which will contain the backup files, for

example:
C:

3. The program creates a subdirectory called \SYS2 for the program and backup files, then copies the program files into this subdirectory. Note: When installing this program under Microsoft Windows, make sure that correct PIF file settings, particularly high foreground priority, are used.

Starting the program

1 Change to the program subdirectory (C:\SYS2) and enter the command The program now begins. START_E 2. Use the TAB key or the mouse to move around the operating screen. 3. Complete program directions are available by pressing the Help key (?) on the SYSTEM 2 computer keyboard or from the instruction manual.
IBM is a registered trademark of International Business Machines, Inc. Windows is a registered trademark of Microsoft, Inc.

38 Troubleshooting guide

Troubleshooting checklist
SYSTEM 2 is designed to withstand a rough industrial operating environment. Should you nonetheless encounter difficulty someday, the following checklist of possible problems can be a great help in locating and eliminating the source of trouble. 1. Thermal effects on the SYSTEM 2 computer can result in unsatisfactory measurement accuracy and repeatability. This can occur, for example, when the computer is cold and put into operation in a warm environment. Remedy: wait for the computer to adjust to the surrounding temperature. 2. Overheated computer circuits can lead to failure of various components. Therefore, care should be taken to protect the system from extended exposure to heat; please observe the operating temperature limits for the computer: Active (backlit) display: 0C to 45C (32F to 113F) Passive (non-backlit) display: 0C to 50C (32F to 122F) 3. Low battery level does not influence measurement accuracy. As the batteries become depleted, the display flashes a 'battery low' message, giving the user plenty of advance warning to finish the job at hand before replacing batteries. 4. If the error message No files of this type appears when loading a file, check the RAM memory card in slot 3. 5. The SYSTEM 2 working memory is non-volatile; even when switched off, it retains all configuration and measurement data until these are changed. Therefore, if the program or filer cards are changed, the computer displays a warning that this new information will overwrite the current memory contents, giving the user one last chance to reinsert the previous cards and save the data. 6. If the computer should ever become inoperative and issue the message Press Softkey 1 to restart program, then press the leftmost key in the bottom row (i.e. to the right of the contrast adjustment key). 7. If the computer refuses to start when the ON/OFF key is pressed, check the following possible sources of difficulty: If the battery is depleted, the computer shuts off automatically and cannot be switched back on until connected to its charger/power supply. Check to be sure that the program card in slot 1 (as well as an additional working RAM card in slot 4, if the program requires one) are properly inserted.

39 Troubleshooting guide

The lithium battery in the program card could be depleted. In that case, consult your Prftechnik dealer for further assistance. If the temperature within the computer housing rises above 55 C (131 F), the computer shuts off immediately. Allow the computer to cool off before switching it back on. 8. If the printer (internal or external) does not begin to print with the upper left key is pressed on the computer, check the printer setting (internal/external) in the 'Config.' menu. 9. If the program or working RAM card is removed during operation, the computer may shut off and refuse to start again when the ON/OFF key is pressed. In that case, insert a different program card (with the proper working RAM in place, if necessary), then press the ON/OFF key.

40 SYSTEM 2 Application programs

SYSTEM 2 Application programs

The following application programs are currently available for SYSTEM 2:

OPTALIGN 1.5

and

TURBALIGN 1.5:

Shaft alignment using classic OPTALIGN sensors, for 2 to 5 couplings at a time, with visible Class I or invisible Class II laser beam.

TURBALIGN
Shaft alignment featuring simultaneous measurement of up to 5 couplings at once, thanks to intelligent TURBALIGN sensors with 5-axis detector, infrared data transmission and high-visibility, long-range Class II visible laser beam.

VIBROSPECT FFT
2-channel frequency analyzer with 1600 lines resolution, 2-plane rotor balancing, machine diagnosis according to ISO 2372 (VDI 2056), condition evaluation of bearings and gears, Bode and Nyquist diagrams, user-configurable transducer jacks, cepstrum analysis, and more.

NOVALIGN 'S'
Laser-optical measurement system for alignment or flatness checking with 1/1000 mm (4/10,000 in.) accuracy, 20 m (65 ft.) range, and infrared data transmission.

PERMALIGN
Laser-optical coordinate measurement system for long-term monitoring of coupled machines (for example, to observe thermal growth).

CENTRALIGN
Laser-optical measurement system for centerline alignment, for example, of turbine bearing pockets (diaphragms) or compressor cam holders with micron accuracy.

41 Technical data

Technical data
Computer LCD screen 224 x 122 mm / 8 3/4" x 4 3/4", resolution 350 x 640 pixels, Fluorescentbacklighting,withcontrastcontrol (Optional:passivedisplaywithoutbacklighting) EGA,forexternaldisplay 34variable-functionkeys(softkeys), 4fixed-functionkeys(hardkeys) RS-232C (standard equipment) Built-ingraphicpinprinter,standardpaperwidth 58 mm / 2 1/4", 230 pixels/line Built-in rechargeable battery 6 V, 2 Ah and/or main battery in carrying case, charger 12 V, 2 A Plug-in, storage capacity 1 MB, preprogrammed with 1 application (such as TURBALIGN ) and operating system Two card slots accept memory cards with 256 kB or 64 kB userdatastorage(servicelife:atleastfouryears). Application-specific

Graphicinterface Keyboard Externalinterface P r i n t e r Power supply Program card Memory card Hardware module

Environmentalprotection Computer housing: IP 52 (drip-proof); printer: IP 30 Operating temperature range Active display: 0 - 45 C / 32 - 113 F Passive display: 0 C - 50 C /32 F - 122 F

Dimensions, W x H x D Approx. 310 x 115 x 260 mm / 12 1/4" x 4 9/16" x 10 1/4" Weight Approx. 3.6 kg / 8 lb.

Standard Carrying Case Functions - Serves as a mobile work station - Powers the computer (when mounted) from its main battery - Charges sensor batteries - Provides storage for all measurement components - Protects all components during transport Dimensions, W x H x D closed Approx. 425 x 555 x 295 mm (163/4"x217/8"x115/8") opened for operation Approx. 425 x 900 x 295 mm (163/4"x351/2"x115/8") Weight Approx. 18 kg / 40 lb. (may vary according to configuration)

42

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43 SYS2Commander

SYS2Commander Instructions Version 2.02

The SYS2Commander program provides convenient handling of SYSTEM 2 data files. It lets you copy data back and forth between the third memory card slot of the SYSTEM 2 computer to a PC hard disk or diskette.

Keyboard operation:
Press the F10 key to activate the menu bar. All functions can then be selected by pressing the cursor arrow keys. Most of the functions can also be selected directly by pressing a combination of the Alt key and the correspondingly marked function letter key. The TAB key may be used to select individual fields (such as serial interface setting).

Display:
# Info Alt+A Quit Alt+X RAM Card Backup Restore Status View Upgrade Alt+B Alt+R Alt+S Alt+V Alt+U Options Rs settings Display Help Cable Backup Restore Upgrade View Status Language RS settings F10 Menu

Alt+X Exit

Alt+F4 Close

List of keyboard commands:

Alt+C Alt+O Alt+H Alt+I Alt+B Alt+R Alt+S Alt+V Alt+U Alt+E Alt+D Alt+X Alt+F4 F10 Memory card menu Options menu Help menu Info Backup Restore Status View Upgrade Serial settings Screen settings Ends the program Closes the currently active window Activates the menu bar

When using this program for the first time:

The Info boxes that appear on the screen may be opened and closed by pressing the Return key or clicking the O.K. field with a pointing device. When you are using this program for the first time, it asks you which serial interface is to be used for connection to the SYSTEM 2 computer. Use your mouse or press the tabulator key to open the dialog field, then use cursor-up and -down keys to toggle between COM1: and COM2:. Press Return to confirm your selection. This selection may be changed later in the menu Options/ Rs Options.

44 SYS2Commander

Info:
Displays program information about the SYS2Commander (version number, order number).

Exit:
Ends the SYS2Commander program and releases the SYSTEM 2 computer from its slave (waiting) status.

Backup:
Backup copies the entire contents of the memory card in slot 3 of the SYSTEM 2 computer via serial interface to the PC harddisk or floppy diskette. First activate the Backup function on the SYSTEM 2 computer (Slot 3 PC). SYSTEM 2 then goes into slave mode and waits to receive all further commands from the PC. When the SYSTEM 2 computer displays the message WAITING FOR PC COMMAND, press the Alt and B keys on the PC at the same time (or use your PCs mouse to select the Backup function) to begin the copying process. Then the number of remaining bytes to be copied is continuously displayed. Once the data are copied, enter the MS-DOS name of the new file created by the PC.

Procedure:

Restore:
Restore is used to copy the stored backup data from the PC back to the card in slot 3 of the SYSTEM 2 computer. This function overwrites (erases) all the old files on the card! Note: NOVALIGN files must be saved before 'Restore' is used!

Procedure:

First activate the Backup function on the SYSTEM 2 computer (Slot 3 PC). SYSTEM 2 then goes into slave mode and waits to receive all further commands from the PC. When the SYSTEM 2 computer displays the message WAITING FOR PC COMMAND, press the Alt and R keys on the PC at the same time (or use your PCs mouse to select the Restore function), then enter the name of the desired PC file to be restored. The copying process begins, and the number of remaining bytes to be copied is continuously displayed.

Status:
The Status function checks the condition of the memory card in slot 3 of the SYSTEM 2 computer, which of course must first be connected to the PC via serial interface. The SYSTEM 2 computer must also be in its Backup mode as described above (under Backup and Restore).

Possible errors:
Status query impossible RAM card missing Faulty RAM card No RAM card

Cause of error:
Incorrect connection of serial interface cable or SYSTEM 2 backup function not started No memory card found in slot 3 RAM card in slot 3 is faulty Invalid card in slot 3

View:
The View function shows a short overview of the card contents stored on the PC. For each individual measurement set in the card file, the name, type, date and time of storage is displayed. The View function can be activated several times to compare the contents of different backup files.

45 SYS2Commander

Upgrade:
The Upgrade function lets you save far more measurement results (particularly vibration spectra) on the very same RAM card. This upgrade function effectively converts your 256 KB RAM card to a High Density (HD) version capable of storing up to 255 vibration spectra or 255 vibration time signals or 100 TURBALIGN 1.5 files (2 machines each) or 40 TURBALIGN files (6 machines each)

Procedure:
1. 2. 3. 4. 5. Back up the RAM card as usual. Select the Upgrade function of SYS2Commander Select the backup file you just made in step 1. The Upgrade function now extends your RAM card capacity. Now you may Restore this converted file to your System 2. To check that all has gone well, insert the restored RAM card in slot 3 of the SYSTEM 2 computer and press the Load or Delete key. The file selector menu should now display the status line HD-RAM C below the file box indicating that the RAM card has been successfully upgraded.

Note: Once upgraded, the RAM card retains its HD-RAM status, even when it is reformatted later. This HD-RAM format is supported by all SYSTEM 2 programs issued after May 1st, 1992.

circumstances should HD-RAM cards be used with the following program versions:
OPTALIGN 1.5 TURBALIGN 1.5 TURBALIGN VIBROSPECT FFT VIBROSPECT FFT with balancing PERMALIGN Version 2.01 and Version 2.01 and Version 2.05 and Version 2.01 and earlier earlier earlier earlier

Under no

Version 1.11 and earlier Version 1.05 and earlier

Starting in December 1992, all RAM cards delivered with new SYSTEM 2 equipment feature the expanded HD format.

Interface:
This function lets you set the port (interface number) to which you have connected the serial cable to the PC. The default setting is COM1.

Screen:
This function lets you set the optimum screen mode for monochrome or black-and-white displays (such as that on a laptop computer). The default setting is Color.

Serial connection:
A 3-conductor cable (RX-TX interchanged) is needed to connect the SYSTEM 2 computer to a PC: order number SYS 2.711

46 Index

Index

A
Amp meter 22, 35 Autooff 22, 34

L
LCD screen 14

M
Measurement accuracy 6 Memory card 4, 16, 31 Formatting 18 Longevity 17

B
Backup 32 Battery 6, 17, 22 Charging 22 Memory card 17

N
New 31

C
Card slots 16 Carryingstrap 24 Case battery 6 Cleaning set 6 Clock 36 Config. 34 Contrast adjustment 35

O
ON/OFF 4 Opening screen 29, 30

SYSTEM 2 Computer 14 Battery 22 Carryingstrap 24 EGA 19 Formatting 18 Main program (Master) 16 Memory cards (RAM) 15 Printer 21 Printerpaper 21 Program cards 16 Ribbon 21 RS-232C 19 Sensorinterface 20 Subprograms (Slave) 16 Switching on 29 Transportcart 11

P
Pinconfiguration 19 Printer 4, 21 Cover 21 Key 4 Paper 21 Ribbon 20 Program structure overview 28

T
Thermometer 35 Trigger Pinconfiguration 19

D
Delete 32

V
Voltmeter 35

E
Editor 30 EGA 4, 19

W
Warranty 6

R
Rename 31 Ribbon 21 RS232-C 4 parameters 34

F
Filehandling 31 Delete 32 Format 18 Load 31 Save measurement parameters 32 Format 18

S
Save 32 Saving measurement parameters 32 Sensorinterface 4, 20 changing 20 Service 6 Switching on 29 System 35 SYSTEM 2 case 7 Opening 7 Closing 9

H
Help key 4 Helptext 30

I
Info 33

K
Keyboard 14

47

SOFTWARE
PLEASE

LICENSE
IMPORTANT

AGREEMENT
SOFTWARE

READ THIS LICENSE AGREEMENT CAREFULLY BEFORE OPENING THE MEDIA ENVELOPE.

RIGHTS ARE OFFERED ONLY ON THE CONDITION THAT THE CUSTOMER AGREES TO ALL TERMS AND CONDITIONS OF THE LICENSE AGREEMENT. TANCE OF THESE TERMS AND CONDITIONS. MAY RETURN THE UNOPENED PACKAGE FOR

OPENING THE MEDIA ENVELOPE IF YOU DO NOT AGREE TO THE A FULL REFUND.

INDICATES YOUR ACCEPLICENSE AGREEMENT, YOU

LICENSE

AGREEMENT

In return for payment of the applicable fee, PRFTECHNIK grants the customer a license to the software, subject to the following:

USE
Customer may use the software on any one computer. Customer may not reverse assemble or decompile the software.

COPIES AND ADAPTATIONS

Customer may make copies or adaptations of the software: a. For archival purposes; or b. When copying or adaptation is an essential step in the use of the software with a computer so long as the copies and adaptations are used in no other manner. Customer has no other rights to copy unless he acquires an appropriate license to reproduce which is available from PRFTECHNIK for some software. Customer agrees that no warranty, installation or training is provided by PRFTECHNIK for any copies or adaptations made by Customer unless otherwise agreed by PRFTECHNIK. All copies and adaptations of the software must bear the copyright notice(s) contained in or on the original.

OWNERSHIP
Customer agrees that he does not have any title or ownership of the software, other than ownership of the physical media. Customer acknowledges and agrees that the software is copyrighted and protected under the copyright laws. Customer acknowledges and agrees that the software may have been developed by a third party software supplier named in the copyright notice(s) included with the software, who shall be authorized to hold the Customer responsible for any copyright infringement or violation of this License Agreement.

TRANSFER OF SOFTWARE RIGHTS

Customer may transfer software rights to a third party only as part of the transfer of all rights and only if Customer obtains the prior agreement of the third party to be bound by the terms of this License Agreement. Upon such a transfer, Customer agrees that its rights in the software are terminated and that it will either destroy its copies and adaptations or deliver them to the third party. Transfer to a U.S. Government department or agency or to a prime or lower tier contractor in connection with a U.S. Government contract shall be made only upon their prior written agreement to terms required by PRFTECHNIK.

SUBLICENSING AND DISTRIBUTION

Customer may not sublicense the software or distribute copies or adaptations of the software to the public in physical media or by telecommunication without the prior written consent of PRFTECHNIK.

TERMINATION
PRFTECHNIK may terminate this software license for failure to comply with any of these terms provided PRFTECHNIK has requested Customer to remedy the failure and Customer has failed to do so within thirty (30) days of such notice.

UPDATES

AND

UPGRADES
10.9388.8.92g

Customer agrees that the software does not include updates and upgrades which may be available from PRFTECHNIK under a separate support agreement.

EXPORT

CLAUSE

Customer agrees not to export or re-export the software or any copy or adaptation in violation of the U.S. Export Administration regulations or other applicable regulation.

48

Proven maintenance technology

PRFTECHNIK AG P.O. Box 12 63 D-8045 Ismaning Tel. (+49) 89 / 99 61 60 Fax (+49) 89 / 99 61 62 00

Printed in Germany OPTALIGN, TURBALIGN, NOVALIGN, CENTRALIGN, Softline, PERMABLOC , LAMIBLOC , VIBROCORD and VIBROSPECT are registered trademarks of PRFTECHNIK AG. Contents subject to change without further notice, particularly in the interest of continuous product development. Copyright 1993 by PRFTECHNIK AG. Reproduction, in any form whatsoever, only with express written consent of PRFTECHNIK AG.