simatec IH 070 Induction Heater Instruction Manual

: September 22, 2024
: simatec

simatec IH 070 Induction Heater

INSTRUCTION MANUAL

MODEL: IH 070/090

EU Declaration of conformity

simatec ag, Stadthof 2, CH-3380 Wangen a. Aare, Switzerland, declares that the

Induction Heater simatherm IH 025 / 045 / 070 / 090 / 210 are designed and manufactured in accordance with
Directive 2014/35/EU of the European Parliament and of the Council on the harmonisation of the laws of the Member States relating to the making available on the market of electrical equipment designed for use within certain voltage limits

Directive 2014/30/EU of the European Parliament and of the Council on the harmonisation of the laws of the Member States relating to electromagnetic compatibility
Directive 2011/65/EU of the European Parliament and of the Council on the restriction of the use of certain hazardous substances in electrical and electronic equipment

The following standards have been applied:

EN 55011: 2016 + A1:2017 + A11 : 2020
EN 60519-3 : 2005 / EN 61000-3-3 : 2013 / EN 61000-6-2 : 2005
EN 62233 : 2008 / EN IEC 63000 : 2018
Wangen a. Aare, 30.05.2024

Mischa N. Wyssmann, Managing Director / CEO
UK Declaration of conformity simatec ag, Stadthof 2, CH-3380 Wangen a. Aare, Schweiz, declares that the
Induction Heater simatherm IH 025 / 045 / 070 / 090 / 210 is designed and manufactured in accordance with the conditions of the following Directives: Electrical Equipment (Safety) Regulations 2016

Electromagnetic Compatibility Regulations 2016

The Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equip-ment Regulations 2012

The following standards have been applied:

EN 55011: 2016 + A1:2017 + A11: 2020
EN 60519-3 : 2005 / EN 61000-3-3 : 2013 / EN 61000-6-2 : 2005
EN 62233 : 2008 / EN IEC 63000 : 2018
Wangen a. Aare, 30.05.2024

Mischa N. Wyssmann, Managing Director / CEO

Safety Recommendations

Because the IH 070/090 generates a magnetic field, people wearing a pacemaker must not be within 5m (16ft) of the IH 070/090 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 070/090 and the workpiece. This is not dangerous to human beings and will not cause damage to the IH 070/090 or the workpiece. However, the IH 070/090 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 070/090 without a yoke in position.
Do not modify the IH 070/090.
Use proper handling equipment when lifting heavy workpieces.
Avoid contact with hot workpieces. Wear the supplied heatresistant gloves to handle hot workpieces.

1. Introduction

The simatec IH 070/090 induction heater is designed to heat bearings that are mounted with an interference fit onto a shaft. The heat causes the bear-ing 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).

1.1 Intended use

The IH 070/090 has been designed to heat rolling bearings. However, oth-er 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 top yoke in place can be heated using the IH 070/090. In addition, smaller bearings can be placed over either of the three standard yokes. See the illustrations at the beginning of this manual for examples.

1.2 Principle of operation

The IH 070/090 generates heat by means of a large electrical current that is magnetically induced in the work-piece 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 wind-ing, the high current generates heat within the workpiece. Because the heat is generated within the workpiece, all of the heater components remain cool.

1.3 Distinguishing feature

The distinguishing feature of the IH 070/090 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.

2. 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).

2.1 Components

The IH 070/090 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 removable yoke on the top of the verti- cal supports allows the workpiece to be placed onto the heater. The top yoke of the IH 090 is mounted on a swivel. To accommodate smaller workpieces, two smaller yokes are also provided. A temperature probe is also included with the heater. Heat-resistant gloves are also included.

2.2 Technical data

3. Installation of mains plug

Due to the many types of mains plugs, no mains plug is supplied with the IH 070/090. 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:

Connect the IH 090 to only two of the three phases. Verify that the correct circuit breaker is installed. See section 2.2 for circuit breaker specifications.

4. Preparation for use

Place the IH 070/090 in the horizontal position on a stable surface.
Connect the mains plug to a suitable mains supply.
For the IH 090 only, follow these steps to install the swivel arm:
– Attach the protection plate (4) to the side post to prevent damage.
– Install the swivel head (1) and the swivel body (2) on the lefthand side post of the heater.
– Install the large top yoke (55 x 55mm) in the swivel head. Adjust the swivel body so that there is no visible gap (A) between the side post and the yoke.
– Tighten the four screws (3) of the swivel body (maximum
torque 5Nm).
– Turn the screw (5) on top of the swivel head to position the top yoke. The top yoke must contact as much of the upper surface of the right-hand side post (B) as possible. Noise during operation could indicate that the top yoke is not positioned properly.
Special notes for the IH 090:
– The yoke support is required when either of the smaller yokes
(28 x 28mm or 14 x 14mm) is installed. Install the yoke
support and the yoke together in the swivel head. If necessary, rotate the swivel head to provide better access.
– Heavy workpieces (≥10 kg/22 lbs) that must be installed on the top yoke should be supported until the yoke is in the correct position on the right-hand side post. The heater may tip over if the workpiece is not supported.
– The swivel body (2) can remain on the heater at all times.
For workpieces with an internal diameter 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.
– Remove the protective film from the bright underside of the top yoke before the first use.
– Position the top yoke 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 three yokes that fit through the internal diameter of the workpiece.
– If necessary, remove the top yoke from the IH 070/090.
– Verify that the protective film has been removed from the underside of the small or medium 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 070/090 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.
Use the power switch on the left side to switch on the IH 070/090.
Observe the self-test of the display and signal tone.

5. Operation

5.1 Function of displays

A. The main display shows the selected time or temperature for heating.

5.3 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 does not lock due to an excessive expansion of the inner ring compared to outer ring. See section 5.8.
All 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.
Make sure the temperature probe is mounted on the bearing inner ring.
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 demag-netises the workpiece, generates an acoustic signal for 10 seconds 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 070/090 is now ready to heat another workpiece with the same settings.

5.4 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 070/090 is now ready to heat another workpiece with the same settings.

5.5 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.

5.6 Change of temperature unit

Press MODE and UP at the same time to switch between °C and °F. The tem- perature unit setting remains the same even after disconnection from mains power.

5.7 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 070/090 for demagnetisation only, select TIME MODE and set the time to 0.1 minute (6 seconds).

5.8 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 20%power when using the small yoke, 40% power when using the medium yoke, or 60% power when using the large yoke.
When using the small yoke, never exceed 40% power.
When using the medium yoke, never exceed 60% power.

6. Safety features

The IH 070/090 is equipped with the following safety features:

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.
Additionally, the IH 090 is equipped with a main switch with over-current circuit breaker.

7. Troubleshooting

A system fault will be indicated by an acoustic signal and one of the follow- ing fault codes on the main display:

8. Spare parts

Specifications

IH 070:
- Recommended circuit protection: 20A fuse
- Power: 0-60 minutes in 0.1-minute increments, 20-100% in 20%
  increments
- Residual magnetism: < 2A/cm
- Dimensions: 420 x 280 x 345mm
- Weight: 35kg (120kg with packaging)
IH 090:
- Recommended circuit protection: Not specified
- Power: 0-60 minutes in 0.1-minute increments, 20-100% in 20%
  increments
- Residual magnetism: < 2A/cm
- Dimensions: 420 x 280 x 420mm
- Weight: 38kg (150kg with packaging)