Pump Alignment Description
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| Pump and motor alignment professionals
must see and try this new tool. The RRJ ePump Alignment
Toolkit features the latest advances in shaft alignment
technology. As a professional you know that misalignments
cause premature failure of pump bearings leading to costly
repairs and equipment downtime. Since precise alignment
of the pump to the motor is so critical, you have windows
of opportunities to offer alignment services. |
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 There
are other tools available in the market that perform similar
functions. However, you will find the RRJ ePUMP Alignment
Tool is the most cost effective, easiest to use, and most
precise instrument available, especially for field installed
systems.
The toolkit hardware shown in the photographs on this page,
interfaces directly with software written by RRJ engineers.
The software facilitates fast, easy, and extremely accurate
alignment of pumps and motors used in the HVAC industry
and other pump intensive applications.
The toolkit is designed to quickly and easily mount to the
shafts of the pump and motor. Through the use of a bushing,
various size shafts can be easily fitted.
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Toolkit ePUMP-200-U will fit shaft diameters from 1” to
2”. Should you require compatibility for shaft sizes outside
this range, you must specify your needs when you place your
order.
Toolkit ePUMP-200-M will fit shaft diameters from 25mm to
60mm. See photo to the left.
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| RRJ Toolkit PreciseAlign™ Software™
Software |
The alignment is performed with the
included PreciseAlign™ toolkit
software. The intuitive and easy to use software is developed
to be installed on Windows-based PCs. Installation is straightforward
using Instructions found in the toolkit. The software is
compatible with Windows XP or better.
The default blue PreciseAlignn™
front panel background, shown to the right, can easily be
changed to your own color preference with the click of a
button.
The initial view of the PreciseAlignn™
alignment program (click on the image to expand)
displays a graphical representation the pump and motor arrangement.
In this view, the motor represents the moveable component
of the alignment, and the pump is the fixed part. That said,
it is the motor that is aligned vertically and horizontally.
Shims are placed at the motor to align it vertically with
the highest level of precision.
Alignment is accomplished horizontally by physically moving
the motor horizontally by the amount calculated in the software
results (thousandths of an inch). The objective is to align
the pump and motor within .002” of each other.
The criteria you establish will depend on the specific circumstance
and application. However, the greater the misalignment,
the greater the risk of damage to the bearings. At speeds
below 1000 rpm the alignment is not as critical but at higher
speeds such as 3600 RMP, alignment is significantly more
critical. |
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| Mounting the Fixture and Performing
the Alignment |
| Prior to mounting the ePump alignment
fixture, it is recommended to perform an initial alignment
using a straight edge to physically align the two shafts
as closely as possible. The coupling is removed to do this
preliminary alignment. Afterward the coupling is re-secured
and the ePump alignment fixture is mounted into place. |
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| Notice two digital dials are mounted
on the shafts simultaneously. This arrangement is key to
the degree of precision and ease of use of the tool. Two
precision dials from Tesa, each with integrated with USB
interfaces are incorporated and to the design. Therefore,
two free USB ports are required on your PC. The kit instructions
explain how to connect the USB cabling. If your PC only
supports the RS232 interface, call to inquire about options.
Note: The RRJ software only works with the dials supplied
with your RRJ ePUMP Alignment Toolkit order. |
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| There are two windows on the Front Panel
computer display for Front and Rear motor feet shims. These
values change as you rotate the shafts. The software dynamically
calculates the size of shim required for vertical alignment.
Positive numbers are used to add shim values as shown and
negative numbers to remove shim values as shown. The program
does require three measurements to be entered; distance
between dials, distance from dial closest to motor and motor
front feet, and distance between the front and rear feet
of the motor. These are entered as shown on the graphical
display. |
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To begin the alignment, you must position
the dials perpendicular to the shafts. When positioned,
click RESET on the front panel.
This will ZERO the dials. Next, turn the dials 180 degrees.
Please note that you must always turn in the same direction.
Notice the size of the shims indicated on the front panel.
Return the dials to original position to make sure the dials
return to ZERO. If they do not, press
RESET again and turn the dials
180 degrees and then back to the original position again.
However, the dials must return to zero within .001”. If
the dials do not return to ZERO, the stability of the system
has been somehow compromised. This must be resolved before
continuing. Be sure you keep constant torque on the shaft
for stable readings.
For horizontal alignment, simply turn the alignment fixture
to the 270 degree position towards the left or away from
you. ZERO the dials and then turn the alignment fixture
to the 90 degree position or towards you. Notice the display
of shim values. These are dynamic in that, as you move the
motor horizontally, the display will update dynamically.
In this manner you can move the motor until it is within
the .002" criteria. Use the HORIZONTAL
ALIGNMENT HELP button to determine in which direction
to move the motor, dependent on whether you are getting
positive or negative readings. There are also
VERTICAL ALIGNMENT and
PRE-ALIGNMENT HELP buttons.
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 During
alignment, shims are inserted or removed. You may find yourself
going back and forth as you get closer to the .002” criteria.
It is not uncommon for the alignment to take several iterations.
Ensure that constant and repeatable torque on the motor
mounting bolts is being applied.
You should notice the shim values display changes. These
are dynamic in that, as you move the motor horizontally,
the display will update automatically. In this manner you
can adjust the motor position until it is within the .002”
criteria.
The entire process is simple and extremely accurate. |
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| Comments and Tips |
Alignment is an art, in and of itself.
People who offer, or intend to offer pump alignment services
must be aware of the on different causes of miss-alignment,
and how to move motors and pumps, and additional circumstances
that can affect accurate and proper alignment. This knowledge
can be obtained by practical industry experience and research
reading.
Be aware that if a motor is cocked, for example, you will
never get to within .002” without resolving the issue. In
fact, in our video example, the front left foot .005” higher
than the front right foot. This was determined because the
RRJ software kept hovering around .008” when trying to achieve
alignment. There is a simple way to determine if the motor
is cocked. Contact RRJ if you wish to discuss this further.
You can see that with the RRJ toolkit, alignment is made
relatively simple. Using other brands of equipment it may
take hours to simply check the alignment of a similar system.
With the RRJ toolkit, you can check the alignment in minutes
with exacting precision. In reality, the time required to
install the fixture and connect the PC, is typically longer
than performing the actual alignment. These features make
make the RRJ toolkit a powerful and cost effective tool
to implement as part of your maintenance programs. |
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| Even factory pre-aligned pump systems
must be checked for alignment after on-site installation
due to possible transportation mishandling. Additionally,
systems must be checked periodically due to thermal growth.
The RRJ ePump Alignment Toolkit is an easy to use,
inexpensive tool for these purposes as well.. |
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| Alignment Logging and E-Mail Plug-Ins
for PreciseAlign™ Software
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The RRJ ePA Maintenance Logger is an
included plug-in for the ePump Alignment software. When
you choose to activate it, the ePA Maintenance Logger automatically
stores a permanent record of the alignment just completed.
The Vertical and Horizontal alignment record is saved to
a file. An additional option can be configured to email
alignment records to designated email addresses.
The System ID, the Service Tech ID, Vertical and Horizontal
values, and date/time are logged. Purchase this great tool
to include in your Preventative Maintenance programs.
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| Elements reported by the
ePA Maintenance Logger |
| Contractor: |
Pump Alignment Service
Company |
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| Customer: |
Pumps-R-Us
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| Time/Date |
Site Name |
Pump Number |
Field Tech |
Position |
Front Shim Value |
Rear Shim Value |
| 10/24/2010 17:01 |
North Building |
1234 |
John Service |
Vertical |
0.002 |
0.001 |
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| Order Today - Choose
the Toolkit that Best Fits Your Needs |
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 Standard
Edition Toolkit
The Standard RRJ ePump Alignment Toolkit, shown
left, is packaged in a rugged oil-proof carrying case. Click
on the photograph to enlarge.
Premium Edition Toolkit
The Premium Edition RRJ ePump Alignment Toolkit includes
a laptop computer pre-loaded with the alignment software.
A complete turnkey solution packaged in a single rugged
carrying case.
For pricing information and orders email or call 505-259-0244.
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