simatec IH 210 Induction Heater Instruction Manual
- June 9, 2024
- simatec
Table of Contents
simatec IH 210 Induction Heater
Safety recommendations
- Because the IH 210 generates a magnetic field, people wearing a pacemaker must not be within five meters of the IH 210 during operation. Electronic equipment, such as wristwatches, may also be affected.
- Follow the operating instructions at all times.
- Be certain that the voltage supply is correct.
- Electrical arcing may occur when a potential difference exists between the IH 210 and the workpiece. This is not dangerous to human beings and will not cause damage to the IH 210 or the workpiece. However, the IH 210 must never be used in areas where there is a risk of explosion.
- Do not expose the heater to high humidity.
- Never operate the IH 210 without a yoke in position.
- Do not modify the IH 210.
- Use proper handling equipment when lifting heavyworkpieces.
- Avoid contact with hot workpieces. Wear the supplied heatresistant gloves to handle hot workpieces.
Introduction
The simatec IH 210 induction heater is designed to heat bearings that are
mounted with an interference fit onto a shaft. The heat causes the bearing to
expand, which eliminates the need to use force during installation. A 90°C
(194°F) temperature difference between the bearing and shaft is generally
sufficient to enable installation. At an ambient temperature of 20°C (68°F),
the bearing must therefore be heated to 110°C (230°F).
Intended use
The IH 210 has been designed to heat rolling bearings. However, other metal
workpieces that form a closed circuit can also be heated. Examples of
acceptable workpieces include bushings, shrink rings, pulleys, and gears. All
bearings that fit over the inductive coil and between the vertical supports
with the sliding yoke in place can be heated using the IH 210. In addition,
smaller bearings can be placed over either of the two standard yokes. See the
illustrations at the beginning of this manual for examples.
Principle of operation
The IH 210 generates heat by means of a large electrical current that is magnetically induced in the workpiece by a coil within the heater. The high voltage, low current electricity flowing through the large number of windings in the inductive coil induces low voltage, high current electricity in the workpiece. Because the workpiece has the electrical characteristics of a coil with a single, short-circuited winding, the high current generates heat within the workpiece. Because the heat is generated within the workpiece, all of the heater components remain cool.
Distinguishing feature
The distinguishing feature of the IH 210 induction heater is the location of the workpiece at the same position on the core as the inductive coil. This design improves efficiency, resulting in less power consumption and faster heating, which reduces the cost to heat each bearing.
Description
The operation of the heater is controlled by the internal electronics in
either of two modes. The operator can either select the desired temperature of
the bearing in TEMP MODE or set the length of time that the bearing will be
heated in TIME MODE. The power level can be adjusted in steps of 20% for
slower heating of sensitive workpieces (for example, bearings with C1 or C2
clearance).
Components
The IH 210 induction heater contains a U-shaped iron core with an inductive
coil surrounding one of the vertical supports. Internal electronics control
the operation of the heater. A sliding yoke on the top of the vertical
supports allows the workpiece to be placed onto the heater. To accommodate
smaller workpieces, a small yoke is also provided. A temperature probe is also
included with the heater. Heat-resistant gloves are also included.
Technical data
- Designation IH 210 / 200–230 V (Art. 110.1502) IH 210 / 400–480 V (Art. 110.1501) IH 210 / 575 V (Art. 110.1503)
- Recommended circuit protection 50A circuit breaker (200-230 V) 32A circuit breaker (400-480 V) 25A circuit breaker (500-575 V)
- Power consumption (maximum) 8.0 kVA (200 V/ 50-60 Hz) 11.5 kVA (400–480 V/ 50–60 Hz) 10.4 kVA (575 V/ 50–60 Hz)
- Temperature control 0–250°C (32-482°F) in steps of 1°
- Probe maximum temperature 250°C (482°F)
- Time mode 0–60 minutes in steps of 0.1 minute
- Power range 20 – 100% in steps of 20%
- Demagnetisation, automatic Residual magnetism < 2A/cm
- Overall dimensions 600 x 350 x 420mm
- Area between supports 250 x 250mm
- Coil diameter 135mm
- Weight (with yokes) 75kg
- Workpiece maximum weight Bearing 300kg, solid component 150kg
- Maximum heating temperature approx. 400°C (752°F)
- Standard yoke dimensions 70 x 70 x 420mm (for Ø of 100mm) 40 x 40 x 420mm (for Ø of 60mm)
Installation of mains plug
Due to the many types of mains plugs, no mains plug is supplied with the IH 210. A qualified electrician must install a suitable mains plug. The correct supply voltage is shown in section 2.2. The wires should be connected as follows:
Colour of IH 210 wire Mains supply terminal
- yellow/green (green) Protection earth (PE)
- brown („1“ or black) Phase 1 (L1)
- blue („2“ or white) Phase 2 (L2)
Connect the IH 210 to only two of the three phases. Verify that the correct cicuit breaker is installed. See section 2.2 for circuit breaker specifications.
Preparation for use
- Place the IH 210 in the horizontal position on a stable surface.
- Connect the mains plug to a suitable mains supply.
- For workpieces with an internal diameter (>135mm) large enough to fit over the inductive coil, follow these steps:
- Place the workpiece over the inductive coil using appropriate lifting equipment.
- For best performance, adjust the position of the workpiece so that the inductive coil is in the centre.
- If the sliding yoke is not installed on the IH 210, follow the steps shown in the illustrations at the beginning of this manual.
- Remove the protective film from the bright underside of the sliding yoke before the first use.
- Slide the sliding yoke to the right so that it completely covers the top of both vertical supports.
- For workpieces that do not fit over the inductive coil, follow these steps:
- Choose the larger of the two yokes that fit through the internal diameter of the workpiece.
- If necessary, remove the sliding yoke from the IH 210.
- Verify that the protective film has been removed from the underside of the small yoke if it is to be used for the first time.
- Slide the workpiece onto the yoke that you have selected.
- Position the yoke on the IH 210 with the bright underside resting evenly on the two vertical supports.
- If you will use TEMP MODE, plug the temperature probe into the connector on the left side of the heater. Place the magnetic end of the probe on the inner ring of the bearing or on the innermost surface of the workpiece.
- Switch the IH 210 on using the power switch on the left side.
- Observe the self-test of the display and signal tone.
Operation
Function of buttons
Button Function
- POWER Press to adjust the power in steps of 20%. The selected power is indicated on the power display.
- MODE Press to switch between TIME MODE and TEMP MODE.
- UP (+) Press to increase the value shown on the main display.
- DOWN (-) Press to decrease the value shown on the main display.
- START/STOP Press to start or stop the heater. The LED on the START/STOP button is lit when the heater is heating and flashes during temperature measurement.
Temp mode
- If the main display shows ‘t’, press MODE to select TEMP MODE. The main display shows °C or °F in TEMP MODE.
- The selected temperature is shown on the main display. The default temperature for bearings is 110°C (230°F). If a different temperature is desired, press UP or DOWN to adjust the temperature in steps of 1°. It may be desirable to heat bearings to temperatures above 110°C (230°F) for increased mounting time. Consult the bearing specifications to determine the maximum permitted temperature. Always ensure the bearing doesn‘t lock due to an excessive expansion of the inner ring compared to outer ring. See section 5.8.
- Spherical Roller Bearings (SRBs) are subjected to a special heat treatment. These bearings can be operated at temperatures as high as 200°C (392°F). Heating these bearings above 110°C (230°F) will not cause any damage as long as the bearing is still able to rotate. For other bearings, a temperature of 125°C (257°F) must not be exceeded unless otherwise specified.
- Press POWER to select the power level. Use the guidelines in section 5.8 to determine the correct power setting.
- Press START/STOP to start the heater. The main display shows the current temperature of the workpiece.
- When the selected temperature has been reached, the heater demagnetises the workpiece, switches off, and generates an acoustic signal for 10 seconds or until START/STOP is pressed.
- Press START/STOP to stop the heater.
- Remove the workpiece with proper handling equipment.
- If the workpiece remains on the heater, the heater will start again when the temperature of the workpiece drops 10°C (18°F). Press START/STOP to stop the heater and demagnetise the workpiece.
- The IH 210 is now ready to heat another workpiece with the same settings.
Time mode
- If the main display shows °C or °F, press MODE to select TIME MODE. The main display shows ‘t’ in TIME MODE.
- Press UP or DOWN to adjust the time in steps of 0.1 minute.
- Press POWER to select the power level. Use the guidelines in section 5.8 to determine the correct power setting.
- Press START/STOP to start the heater. The main display shows the time that remains.
- When the time has elapsed, the heater demagnetises the workpiece, switches off, and generates an acoustic signal for 10 seconds.
- Press START/STOP to cancel the acoustic signal and stop the heater.
- Remove the workpiece with proper handling equipment.
- The IH 210 is now ready to heat another workpiece with the same settings.
Temperature measurement
When the heater is not operating, the temperature of the workpiece can be measured by pressing MODE and START/STOP at the same time. The LED on the START/STOP button flashes during temperature measurement. Press START/STOP to cancel temperature measurement.
Change of temperature unit
Press MODE and UP at the same time to switch between °C and °F. The temperature unit setting remains the same even after disconnection from mains power.
Demagnetisation
The workpiece is automatically demagnetised when heating is complete. Demagnetisation will not occur if the power is interrupted or the main switch is switched off. To use the IH 210 for demagnetisation only, select TIME MODE and set the time to 0.1 minute (6 seconds).
Power level selection
When heating bearings with an induction heater, most of the heat will be generated in the inner bearing race. The heat will then be transferred through the bearing. It is therefore important that bearings with small internal clearance or slight preload are heated slowly. Slow heating ensures that the bearing expands evenly, thereby preventing damage to the bearing. The shape, weight, size, and internal clearances all affect the amount of time required to heat a bearing. The large variety of bearing types precludes the possibility of providing a specific power level setting for each type. Instead, the following guidelines are provided
- For sensitive bearings (including bearings with C1 or C2 internal clearance) or bearings with brass cages, do not exceed 40% power when using the small yoke or 60% power when using the sliding yoke.
- When using the small yoke, never exceed 60% power.
Safety features
The IH 210 is equipped with the following safety features:
- Main switch with overcurrent circuit breaker
- Automatic overheating protection
- Automatic current control
- In the TEMP MODE the heater will switch off if the temperature probe does not register a temperature increase of 1° every 15 seconds. To increase the interval to 30 seconds, press MODE and DOWN at the same time.
Troubleshooting
A system fault will be indicated by an acoustic signal and one of the following fault codes on the main display:
Display Fault Action
- E01 E General system failure Return heater for repair.
- E02 E Memory failure Return heater for repair.
- E03 E Overheated coil Wait until the inductive coil cools.
- E04 E not in use
- E05 E Temperature increase of less than 1° every 15 seconds (or 1° every 30 seconds) Check the temperature probe connection. If the connection is OK, select the 30 second interval as described in section 6 or operate the heater in TIME MODE.
- E06 E Temperature probe not connected (or defective) Check the temperature probe.
- E07 E Failure during current measurement Return heater for repair.
- E08 E Failure during communication with power printed circuit board Return heater for repair.
- E09 E Overheated printed circuit board Wait until the printed circuit board (PCB) has cooled down
Spare parts
Art. No. Description
- 190.1005 IH 090/210-P Power print 400-575V/50-60Hz
- 190.1402 IH 210-P/200V Power print 200-230V/50-60Hz
- 190.1401 IH 210-C Coil 400-460V/50-60Hz
- 190.1409 IH 210-C/200V Coil 200-230V/50-60Hz
- 190.1410 IH 210-C/500V Coil 500-575V/50-60Hz
- 190.7402 IH 210-CP Control print 400-460V
- 190.7401 IH 210-CP/200V Control print 200-230V
- 190.7405 IH 210-CP/500V Control print 500-575V
- 190.7403 IH 210-H Heating pad incl. sealing
- 190.1403 IH 210-S Main switch 25A/400-460V
- 190.1411 IH 210-S/200V Main switch 50A/200-230V
- 190.1412 IH 210-S/500V Main switch 20A/500-575V
- 190.1408 IH 210-Y100 Yoke 70 x 70 x 420mm (for bearings with minimum 100mm bore)
- 190.1405 IH 210-Y80 Yoke 55 x 55 x 420mm (for bearings with minimum 80mm bore)
- 190.1404 IH 210-Y60 Yoke 40 x 40 x 420mm (for bearings with minimum 60mm bore)
- 190.7404 IH 210-YH Yoke roller housing
- 190.1406 IH 210-YS Set support yoke 70 x 70 x 150mm
- 190.1001 IH P2 Temperature probe, K type
Swiss made by:
simatec ag Stadthof 2 3380 Wangen a. Aare Switzerland
www.simatec.com