November 27, 2025
Safety at All Levels
Precise alignment meets intrinsically safe technology: Easy-Laser uses the intrinsically safe Tab-Ex® 03 tablet for exact shaft alignment of rotating machines in Zone 1/21 and Div. 1 hazardous areas.
In demanding industrial environments such as refineries, power plants, or chemical plants, one thing is particularly important: machines must operate reliably around the clock to ensure safe processes and avoid unplanned downtime. That is why more and more companies make use of predictive maintenance. The precise shaft alignment of rotating machines plays a crucial role in this. Even the slightest deviations in the tenth of a millimeter range can lead to excessive stress on bearings and couplings in the long term, which can result in costly damage and downtime.
The XT550 alignment system from Swedish manufacturer Easy-Laser AB offers a solution to this problem: It enables high-precision alignment of shafts and was developed specifically for use in explosion-hazardous areas (Zone 1/21 and Div. 1). The key component of the mobile application is the intrinsically safe Tab-Ex 03 tablet from Pepperl+Fuchs.
As one of the leading suppliers of laser alignment systems for rotating machines, Easy-Laser delivers around 1,500 systems annually to over 80 countries—including energy suppliers, steel mills, paper mills, and waterworks. There, the combination of precise laser technology and industrial tablets ensures that machines are optimally aligned, weak points are detected early, and unplanned downtime is avoided.
Easy-Laser's shaft alignment system ensures that rotating machines such as pumps or compressors remain precicely aligned at all times. The Tab-Ex 03 tablet is used to guide maintenance personnel through the alignment process.
The units utilize dot-type laser and 1-axis square PSD surfaces. A state-of-the-art OLED display shows the angle of the unit, making it easier to position it on the shaft.
The system comes in a rugged storage box.
Shaft Alignment Made Easy
To ensure reliable plant operation over the long term, the rotating axes of two coupled machines, such as a motor and a pump, must be aligned as precisely as possible—and under real conditions in the field. This is where shaft alignment comes into play: Instead of working with feeler gauges or rulers, modern companies rely on laser-based alignment systems such as the XT550 from Easy-Laser. Two laser units precisely measure the position of the shafts in relation to each other, accommodating hard-to-reach couplings and confined spaces. The app developed by Easy-Laser on the Tab-Ex 03 series tablet from Pepperl+Fuchs guides maintenance personnel step by step through the process: from measurement and adjustment to final inspection. To accurately capture concentricity data, the shaft is rotated slowly, either manually or using an auxiliary motor. “Our systems ensure that rotating machines such as pumps or compressors remain precisely aligned at all times—both during commissioning and as part of regular servicing,” explains Peter Sandström, Head of Product Management at Easy-Laser.
The shafts are checked at least once a year, and even weekly in particularly sensitive areas. The systems are easy to mount on machines and are protected against water and dust in accordance with IP66/67. “Important components are made of aluminum and stainless steel to deliver precise measurement results even under demanding ambient conditions,” adds Sandström.
Around 10–15 % of Easy-Laser's customers require system solutions that are approved for explosion-hazardous areas up to Zone 1/21 according to ATEX and IECEx. In such environments, there is a risk of flammable gases, vapors, or dusts occurring in ignitable concentrations. This means that conventional industrial tablets are not suitable for the XT550 system; only intrinsically safe devices with special approval can be used.
No Compromises in Hazardous Areas
For Easy-Laser, it wasn't just the prevailing conditions that played a decisive role in selecting a suitable tablet provider. Strict requirements were also imposed in terms of general robustness, for example if the device were to be dropped, and ease of use. In addition to ATEX approval, usability in the field was also a key focus," recalls Hans Lissau, Enterprise Mobility Sales Manager for Northern and Eastern Europe at Pepperl+Fuchs, referring to Easy-Laser's criteria. The device displays had to be easy to read even in direct sunlight and easy to operate with gloves or even wet hands. “Here in Scandinavia in particular, cold, damp conditions and operating with gloves on are part of everyday working life,” emphasizes Sandström. The battery performance also had to be impressive, with at least ten hours of continuous operation under full load.
From Toolbox to Tablet
The decision to opt for the Tab-Ex 03 from Pepperl+Fuchs was quickly made. This intrinsically safe 8-inch tablet is based on the proven Samsung Galaxy Tab Active3 and is specially approved for use in hazardous environments up to Zone 1/21. With its sophisticated design, a replaceable 5,050 mAh battery for up to eleven hours of runtime, and a particularly bright, glove-compatible touch screen, it meets all requirements for mobile industrial use.
In combination with Easy-Laser's XT Alignment app, the tablet becomes an intuitive user interface for aligning rotating machines. It guides you step by step through the measurement and adjustment process, stores the data, including photos from the integrated 13-mega-pixel camera, and supports service personnel on site in creating comprehensive reports.
Notably, the Bluetooth® connection to the sensor units and the connection to cloud systems remained consistently stable during practical use. “This was also one of the decisive criteria, as Wi-Fi use is often not approved in many plants for safety reasons,” says Lissau.
In combination with Easy-Laser's XT Alignment app, the intrinsically safe Tab-Ex 03 tablet becomes an intuitive user interface for aligning rotating machines.
Secure by Design
The combination of biometric authentication and the Samsung Knox security solution integrated into the Tab-Ex 03 offers users a high level of data and device security. Samsung Knox enables IT administrators to easily and securely deploy, manage, and secure company-owned mobile devices. At the same time, sensitive information remains permanently protected against threats such as malware or phishing. This ensures that only authorized users have access to internal company data at all times and that this data remains protected even if a device is lost.
Watch Video
Watch the demo video of the laser-based shaft alignment system.