Document title Instruction – Laser Alignment
Document no 5.1 Valid from 30.06.2014
Author GMA / SMPE Approver GMA / PHJ Doc. type Instruction
1.0 Purpose
This instruction is made to eliminate faults and ensure that Grundfos service is performed in a
uniform way globally. It is intended as a back-up to the report/checklist which means that in case
of doubt, this instruction describes what to do.
2.0 Scope
This instruction is made for the service product Laser Alignment. When a Grundfos sales/service
company or an ASP is visiting a customer to perform a Laser Alignment on the products
mentioned in section 8.0.
3.0 Responsibilities
It is the responsibility of Corporate Service to secure that the checklist/report and instruction is
up to date.
The Service Manager is responsible for the service technician having the competences to do so.
The service Technician who carries out the commissioning on site is responsible for the
commissioning and report/checklist being carried out and completed according to the
instruction. Also responsibly to communicate to Corporate Service that if information is missing
in relation to the checklist.
4.0 Instructions
This instruction cannot stand alone; it should always be backed up by the different installation
and operating instructions for the products covered; see section 8.0.
As a rule, all tests and checks in this report should always be cleared with the owner / operator to
ensure that Grundfos personnel do not interfere with the operation of the system the pump is
installed in.
Preliminary check
• Pump and motor nameplate
Motor type: _______________
Pump type:_______________
Pump number:_______________
Q (m3/h): _______________
H (m): _______________
P2 (kW): _______________
n (min-1): _______________
Locate the nameplate on the pump and motor, and write down all information according to the
above. It is important that all information is noted.
1
Check of Installation
• Check the foundation
Check that the pump is installed on a plane and rigid foundation which is strong enough to
provide permanent support for the entire pump.
• Check set-up and alignment of the pump assembly
Use an engineer’s spirit level and ruler as a guide to check that the pump assembly is aligned
in order to avoid damage to the pump shaft and shaft seal during start-up; also check that
the pump installation is level both vertically and horizontally.
• Check the pipeline installation
Check the piping (suction, discharge, drain and flushing pipes) and check that the pump or its
connecting sleeves do not support the pipeline. Check all installed valves and activate them.
• Check expansion and vibration damping equipment
Check the condition, correct function and installation of the expansion joints and vibration
dampers, if installed.
• Check the electrical installation
Check the placing and condition of the cable and control panel.
Comments
Enter any comments on the 5 check points above; e.g. if the pump is supporting the pipe, it is
mentioned here that the pump is supporting the pipe and that this should be corrected as the
alignment could otherwise be affected.
Adjustment/Start-up
• Check application conditions
Operating data (if familiar)
Pumped liquid:_______________
Flow (m3/h): _______________
Head (m): _______________
Temperature (°C): _______________
Write down all accessible data regarding the application; if necessary, speak to the daily
operator to get exact data. Make sure that the pump will operate under the mentioned
conditions only. These conditions apply to (e. g.) pressure, temperature and pumped liquid.
• Check that the pump is filled with the pumped medium
Open the valves to ensure there is free flow of the pumped medium, and make sure that all
air is vented from the pump and suction pipe; see the manual for further instruction on how
to vent the pump.
• Measure the pump and motor temperature
Pump temp.: (˚C):_______________
Motor temp.: (˚C):_______________
Measure the temperature of the pump housing and motor housing and note the result. In
order to perform a good alignment of the pump and motor, the temperature should be
similar to normal operating temperature; therefore we need to log the temperature.
• Check failure-free impeller running
MAKE SURE THE CIRCUIT BREAKER IS SWITCHED OFF!
Remove the fan cover on the motor or the coupling guard on the pump. Check the direction
of rotation (arrow) and rotate the shaft slowly by hand via the fan or coupling. The shaft
must rotate easily. Put the fan cover or coupling guard back on.
• Check correct installation of the coupling (distance between shafts)
2
Check that the distance between the pump shaft and motor shaft is correct. It is important
that there is room for temperature expansion; we recommend the same distance as for the
coupling halves.
Check the distance between the two coupling halves according to the coupling type; see the
table in the IO for the relevant product.
• Perform Laser Alignment of the pump and motor
To make a good alignment, the pump must be filled with the pumped medium as mentioned
above; also, the pump and medium should have operating temperature if possible. If it is not
possible to achieve operating temperature in the medium, perform a preliminary (cold)
alignment and then perform a final alignment after 1 hour of operation. If this is still not
100% correct, Grundfos should visit the site again.
Follow the link for detailed instructions.
http://net.grundfos.com/Appl/WebCAPS/LiteratureDetail?documentid=91559&litlanguag
e=ENU&typecode=&appcode=GENERAL&pdfid=1073176&language=ENU.
Follow the link for a service video.
http://net.grundfos.com/Appl/WebCAPS/LiteratureDetail?documentid=42117&language=E
NU
1 2
Make a rough alignment of the pump and motor using Fasten one laser bracket on the coupling half of the
a straight-edge and feeler gauge, and tighten the pump.
foundation screws to the correct torque. See page 34.
3 4
Fasten the other laser bracket on the coupling half of the Laser unit S (Stationary) is on the stationary part. Laser
motor. unit M (Movable) is on the part that is moved.
3
5 6
Interconnect the laser units, and connect one laser unit Make sure that the laser units are at the same height.
with the control box.
7 8
Measure the distance between the white lines on the Enter the distance.
laser units.
9 10
Measure the distance between the S unit and the centre Enter the distance.
between the couplings.
4
11 12
Measure the distance from the S unit to the first Enter the distance.
foundation screw of the motor.
13 14
Measure and enter the distance from the S unit to the The control box shows that the laser units must be turned
rear foundation screw of the motor. to position 9 o'clock.
15 16
Turn the laser units to position 9 o'clock. Confirm on the Turn the laser units to position 12 o'clock. Confirm on the
control box. control box.
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17 18
Turn the laser units to position 3 o'clock. Confirm on the control box.
19 20
Result of measurement. If the measured values are less Adjust the position of the motor. Slacken the foundation
than 0.1 mm, the alignment is finished. Go to step 24. screws of the motor.
21 22
Place shims with the required thickness. Tighten the foundation screws to the correct torque
again.
6
23 24
S2
Repeat the alignment until the values are within the Check the distance S2. Correct distance, see page 25
tolerances. Go to step 14.
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Result of Laser Alignment:
A mm
B mm
C mm
D mm
Write down the final result from the Laser Alignment in the above table, and attach the file
from the Laser Alignment to the report in SAP. If the Laser Alignment is made after the
operation test, it is these results that must be written down.
• Check and grease the coupling (only valid for greased couplings)
Pack the spaces inside the coupling with as much lubricant as possible and wipe off the
excess; the coupling must be completely filled. Check that the seals on covers line up with the
grooves in the cover. Position gaskets on the flanges of the lower cover half, assemble the
covers around the coupling, and tighten them accordingly. Make sure that the gaskets stay in
position during this tightening procedure. Once the coupling is completely assembled, remove
both of the lubrication plugs in the cover and insert a lubrication fitting. Then, pump in the
appropriate lubricant until it is forced out of the opposite lubrication hole. Replace the two
lubrication plugs; the installation is complete.
• Check the tightness of connections
Check that all flange bolts, foundation bolts and couplings are tight.
• Additional report with Laser Alignment settings is attached in separate file
Name of file:_________________________________________________
Here the name of the Laser Alignment report (file) is noted in order to be able to locate it
later.
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Operation test
• Start the pump and check for excessive noise (if possible slow rpm.).
Listen for abnormal noise from the pump and motor, and feel for vibrations in the pump and
pipe. If any issues are found, stop and investigate before moving on.
• Check that all motor, pump and coupling screws are tight.
After the operation test, recheck that all flange bolts, foundation bolts and coupling screws
are tight, and retighten if needed.
Recheck the alignment and adjust accordingly - note the result in the above table.
Handover
• Give instructions to the daily operator
Instruct the daily operator in the use (start/stop, venting and maintenance) of the pump and
installation, go through the above checklist together with him and ask if he has any
questions. Remind him of the benefits offered by our recommended spare parts and/or other
relevant service offerings.
• System left ready for operation
Inform the daily operator if there is anything he should have in mind before he starts up the
pump after laser alignment.
Additional info/comments
If there are any additional comments from either the Grundfos technician or the daily operator, they
can be noted here; e.g. if the daily operator is not satisfied with the job done, he can note it here.
_____________________________________________________
Date Signature, Grundfos technician
_____________________________________________________
Date Signature, owner/operator
Make sure the Laser Alignment report /checklist is signed both by the Grundfos technician and
the owner/daily operator.
5.0 Definitions
N/A
6.0 Records
As a standard guideline, the report should be archived for the expected lifetime.
7.0 Changes from last revision
N/A – this is the first version
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8.0 References
Installation and operating instructions for the products below are available on WEBCAPS.
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