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Schaeffler HEATER Series User Manual

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Summary of Contents for Schaeffler HEATER Series

  • Page 1 Induction Heating Devices HEATER User manual...
  • Page 3 The operator software can be developed further and an update is possible free of charge. Changes to the software can lead to adjustments in the user manual. A current version of this user manual can be found at http://medien.schaeffler.com using the search term BA42.

  • Page 4: Table Of Contents

    Temperature sensor..............20 Function ..................21 Operation.................. 22 Operating modes............... 23 Temperature hold mode............. 27 Transport and storage Transport................... 28 Storage ..................32 Commissioning Hazard area................33 Initial stages ................34 Voltage supply ................34 Configuration ................36 BA42 Schaeffler Technologies...
  • Page 5 Maintenance plan ..............69 Decommissioning ....................70 Disposal Regulations ................70 Technical data and accessories HEATER25................. 71 HEATER50................. 72 HEATER100................73 HEATER200................74 HEATER400................75 HEATER800................76 HEATER1600................77 Original accessories..............77 Appendix EU Declaration of Conformity............. 78 Schaeffler Technologies BA42...

  • Page 6: About The User Manual

    Warning of magnetic field Warning of non-ionising, electromagnetic radiation Warning of hot surface Prohibited for persons with heart pacemaker Prohibited for persons with metallic implants Carrying of metallic parts or watches prohibited Observe manual Wear safety gloves Wear safety shoes BA42 Schaeffler Technologies...

  • Page 7: Availability

    The illustrations and descriptions cannot be used as grounds for any claims relating to devices that have already been delivered. Schaeffler Technologies AG & Co. KG accepts no liability for any damage or malfunctions if the device or accessories have been modified or used in an incorrect manner.

  • Page 8: General Safety Guidelines

    Only an electrician is in a position, on the basis of his technical training, knowledge and experience as well as his knowledge of the appropriate regulations, to carry out work on electrical devices correctly and recognise possible hazards. BA42 Schaeffler Technologies...

  • Page 9: Hazards

    ■ ■ stent ■ hip implant ■ knee implant ■ metal plate ■ metal screw ■ dental implant and dentures ■ cochlear implant ■ neurostimulator ■ insulin pump ■ hand prosthesis ■ subcutaneous piercing. Schaeffler Technologies BA42...

  • Page 10: Safety Devices

    ■ The heating of the rolling bearing is continuously monitored. If the specified increase in temperature is not achieved within a certain period, the heating device is switched off by the software. BA42 Schaeffler Technologies...

  • Page 11: Protective Equipment

    Protective equipment Personal protective equipment is intended to protect operating personnel against health hazards. This comprises safety shoes and gloves that are heat-resistant up to +250 °C and these must be used in the interests of personal safety. Schaeffler Technologies BA42...

  • Page 12: Safety Regulations

    Only original accessories and replacement parts may be used. The heating device may only be used in well ventilated rooms. Do not feed the mains connection cable through the U-shaped core. BA42 Schaeffler Technologies...
  • Page 13 The heating device must be switched off using the main switch if it is not in use. Back injuries due to incorrect handling of heavy rolling bearings. WARNING   In the case of heavy rolling bearings, use suitable lifting gear. Schaeffler Technologies BA42...

  • Page 14: Scope Of Delivery

    Designation deviates from the naming system as the component is also used for HEATER50. Heating device Support ledge 55 Grease Temperature sensor, magnetic Lifting tool Gloves Safety guidelines User manuals (German and English) USB stick Figure 1 Scope of delivery Heating device HEATER25 BA42 Schaeffler Technologies...
  • Page 15 – – Minimum inside diameter of rolling bearing. Heating device Support ledge 55 Grease Temperature sensor, magnetic Lifting tool Gloves Safety guidelines User manuals (German and English) USB stick Figure 2 Scope of delivery Heating device HEATER50 Schaeffler Technologies BA42...
  • Page 16 – – Minimum inside diameter of rolling bearing. Heating device Slewing ledge 70 Grease Temperature sensor, magnetic Lifting tool Gloves Safety guidelines User manuals (German and English) USB stick Figure 3 Scope of delivery Heating device HEATER100 BA42 Schaeffler Technologies...
  • Page 17 – – Minimum inside diameter of rolling bearing. Heating device Slewing ledge 100 Grease Temperature sensor, magnetic Lifting tool Gloves Safety guidelines User manuals (German and English) USB stick Figure 4 Scope of delivery Heating device HEATER200 Schaeffler Technologies BA42...
  • Page 18 USB stick – – Minimum inside diameter of rolling bearing. Heating device Vertical ledge 120 Grease Temperature sensor, magnetic Gloves Safety guidelines User manuals (German and English) USB stick Figure 5 Scope of delivery Heating device HEATER400 BA42 Schaeffler Technologies...
  • Page 19 USB stick – – Minimum inside diameter of rolling bearing. Heating device Vertical ledge 150 Grease Temperature sensor, magnetic Gloves Safety guidelines User manuals (German and English) USB stick Figure 6 Scope of delivery Heating device HEATER800 Schaeffler Technologies BA42...

  • Page 20: Accessories

    71. Damage during transit Any damage during transit must be reported as a complaint to the carrier. Defects Any defects must be reported promptly to Schaeffler Technologies AG & Co. KG. BA42 Schaeffler Technologies...

  • Page 21: Description Overview

    U-shaped core This is made from steel and protrudes partially from the housing. In the housing, the primary coil is axially arranged symmetrically around the U-shaped core, Figure 10, page 21. Schaeffler Technologies BA42...

  • Page 22: Temperature Sensor

    The sensor head of the temperature sensor is magnetic and is positioned on the component. The signal is fed via the cable and plug to the device, Figure 9. Sensor head Cable Plug Figure 9 Temperature sensor BA42 Schaeffler Technologies...

  • Page 23: Function

    The electromagnetic field is very strong directly at the heating device. The electromagnetic field becomes weaker with increasing distance from the heating device. Primary coil Secondary coil, in this case a rolling bearing U-shaped iron core Ledge Electromagnetic field Figure 10 Function Schaeffler Technologies BA42...

  • Page 24: Operation

    After pressing [ ], the countdown time is counted down, Figure 12. START/STOP Display of countdown time Figure 12 Countdown time Once the countdown time has finished, the electromagnetic field is generated and the rolling bearing is heated. BA42 Schaeffler Technologies...

  • Page 25: Operating Modes

    Always input the time determined in the test.   Destruction of the heating device by heating to a temperature above +240 °C due to input of an excessively long period. Check the current temperature continuously using a temperature   gauge. Schaeffler Technologies BA42...
  • Page 26 The heating time is the time taken until the heating temperature is reached for the first time. The heating time depends on the size of the rolling bearing and the cross-section of the support, slewing or vertical ledge. BA42 Schaeffler Technologies...
  • Page 27 Figure 46, page 60. If temperature hold has been set and the rolling bearing falls below a specified temperature, it is heated again, see page 27. °C Initial temperature Heating temperature Temperature of inner ring Temperature of outer ring Heating time Figure 15 Ramp control Schaeffler Technologies BA42...
  • Page 28 27. °C Initial temperature Heating temperature Temperature of inner ring Temperature of outer ring Heating time Calculation period Maximum temperature differential Figure 16 Delta-T control BA42 Schaeffler Technologies...

  • Page 29: Temperature Hold Mode

    If temperature hold is not maintained, temperature hold will stop once the temperature hold time has ended and the rolling bearing will cool again, Figure 18. °C Heating temperature Limit temperature Figure 18 End of temperature hold Schaeffler Technologies BA42...

  • Page 30: Transport And Storage

    Hazard of falling injuries as a result of tripping due to hanging down WARNING of the mains connection cable.   Secure mains connection cable against dropping during transport. Lifting tool Cotter pin Mains connection cable Figure 19 Transport of HEATER25 and HEATER50 BA42 Schaeffler Technologies...
  • Page 31 Hazard of falling injuries as a result of tripping due to hanging down WARNING of mains connection cable. Secure mains connection cable against dropping during transport.   Lifting tool Mains connection cable Figure 20 Transport of HEATER100 Schaeffler Technologies BA42...
  • Page 32 Secure mains connection cable against dropping during transport.   Lifting tool, transport eyelet Lifting tool, transport handle Retaining nut Mains connection cable Figure 21 Transport of HEATER200 BA42 Schaeffler Technologies...
  • Page 33 Heating device HEATER400 HEATER800 Damage to or separation of the mains connection cable hanging down. Secure mains connection cable against dropping during transport.   Fork spacing Mains connection cable Figure 22 Transport of HEATER400 and HEATER800 Schaeffler Technologies BA42...

  • Page 34: Storage

    Heating device HEATER1600 1 000 Fork spacing Figure 23 Transport of HEATER1600 Storage The safety regulations for storage must be observed, see page 10. A heating device should be stored with protection against dust and UV radiation. BA42 Schaeffler Technologies...

  • Page 35: Commissioning Hazard Area

    Ensure that persons with a ferromagnetic implant remain outside the hazard area of the heating device. Erect barriers and attach clearly visible warning signs, Figure 24.   Hazard area, 2 m Barrier Flat work surface capable of supporting load Figure 24 Hazard area Schaeffler Technologies BA42...

  • Page 36: Initial Stages

    Safety contact socket, 230 V Safety contact plug, 230 V Figure 25 Voltage supply for HEATER25, HEATER50 and HEATER100 CEE plug, 400 V Three-phase plug, 5 pin, 400 V Figure 26 Voltage supply for HEATER200, HEATER400 and HEATER800 BA42 Schaeffler Technologies...
  • Page 37 Fatal electrocution through contact with device if mains connection has been carried out incorrectly.   Mains connection must be carried out by a trained electrician. Phase L1 Phase L2 Protective conductor Figure 27 Mains connection for HEATER1600 Schaeffler Technologies BA42...

  • Page 38: Configuration

    39. USB connector A USB connector is present below the touch-sensitive screen, Figure 28. The following media can be used: ■ USB2.0 stick (up to 32 GB, FAT). USB2.0 connector Figure 28 USB connector BA42 Schaeffler Technologies...
  • Page 39 1: Change to previous parameter 2: Increase value Arrow down 1: Change to next parameter 2: Reduce value Apply Confirm modified value and go back to parameter list Cancel Undo changes and go back to parameter list Schaeffler Technologies BA42...
  • Page 40 T1: 23 [°C] 1:34 PM 1:34 PM BootHWID: BootHWID: 01.01.2000 01.01.2000 0000-0000 0000-0000 v1.00 v1.00 HEATER100 Parameter U26 selected Security question, Apply Do not Do not turn off turn off Figure 30 Flashing Flashing [°C] [°C] Updating firmware BA42 Schaeffler Technologies...
  • Page 41 The control unit can simultaneously store up to 32 user languages. Deleting a user language The user languages cannot be individually deleted. Whenever the user languages are installed, all the languages present on the device are deleted. The languages present in the language package are then installed. Schaeffler Technologies BA42...
  • Page 42 T1: 23 [°C] 1:34 PM 1:34 PM BootHWID: BootHWID: 01.01.2000 01.01.2000 0000-0000 0000-0000 v1.00 v1.00 HEATER100 Parameter U28 selected Security question, Apply Do not Do not turn off turn off Figure 31 Flashing Flashing [°C] [°C] Copying user languages BA42 Schaeffler Technologies...
  • Page 43 With a command parameter, selecting the parameter gives a command that initiates control of the device. An information parameter saves values that can be called up. Schaeffler Technologies BA42...
  • Page 44 – – – – – ● Loading languages – – ● Firmware version – – ● Number of heating operations – – ● Total heating time – – S: Setting parameter C: Command parameter I: information parameter BA42 Schaeffler Technologies...
  • Page 45 Heating temperature: ■ +50 °C, 122 °F Minimum value ■ +110 °C, 230 °F Default setting ■ +240 °C, 464 °F Maximum value ■ Step size. Schaeffler Technologies BA42...
  • Page 46 1 and temperature sensor 2. Values and step size: ■ 1 °C, 33,8 °F Minimum value ■ +35 °C, 95 °F Default setting ■ +100 °C, 212 °F Maximum value ■ Step size. BA42 Schaeffler Technologies...
  • Page 47 99 s Maximum value ■ Step size. Diagram of temperature pattern The last heating curve saved by the device is displayed. The values from which the heating curve was generated can be saved as a file (.csv). Schaeffler Technologies BA42...
  • Page 48 Deleting the favourites list All favourites can be deleted using this command parameter. Setting options: ■ Delete favourites list (default setting) ■ Do not delete favourites list. BA42 Schaeffler Technologies...
  • Page 49 This information may be useful in searching for errors. Total heating time This parameter displays the time for which the device was in operation during all heating operations. This information may be useful in searching for errors. Schaeffler Technologies BA42...

  • Page 50: Operation Selecting A Heating Device

    2 000 Selecting a support ledge If a support ledge is used whose cross-section is too small, the heating device cannot carry out heating at full power:  Select the support ledge with the largest possible cross-section. BA42 Schaeffler Technologies...

  • Page 51: Changing The Slewing Ledge

    Place the new slewing ledge from above on the locating stud.  Position the slewing ledge on the U-shaped core.  The slewing ledge has been changed. Slewing ledge U-shaped core Figure 33 Locating the slewing ledge Schaeffler Technologies BA42...

  • Page 52: Changing The Vertical Ledge

    Mounting the vertical ledge  Mount the vertical ledge from above in the ledge guide using a suitable lifting device.  The vertical ledge has been changed. Vertical ledge U-shaped core Figure 35 Mounting the vertical ledge BA42 Schaeffler Technologies...

  • Page 53: Positioning The Rolling Bearing

    The rolling bearing is positioned suspended from the support ledge. Mass, maximum Designation Mass Heating device Support ledge max. HEATER25, HEATER50.LEDGE-10 HEATER50 HEATER50.LEDGE-15 HEATER50.LEDGE-20 HEATER100 HEATER100.LEDGE-15 HEATER100.LEDGE-20 HEATER200 HEATER200.LEDGE-20 Rolling bearing Support ledge Figure 36 Rolling bearing suspended, support ledge Schaeffler Technologies BA42...
  • Page 54 Lower the rolling bearing.  Remove the carrying sling.  The rolling bearing is positioned suspended from the slewing ledge. Mass, maximum Designation Mass max. HEATER100 HEATER200 Rolling bearing Slewing ledge Figure 37 Rolling bearing suspended, slewing ledge BA42 Schaeffler Technologies...
  • Page 55 Rotate the slewing ledge so that it is fully located on the U-shaped core.  The rolling bearing is positioned lying flat. Slewing ledge U-shaped core Rolling bearing Sliding table Figure 39 Rolling bearing lying flat, slewing ledge Schaeffler Technologies BA42...
  • Page 56 U-shaped iron core.  Lower the vertical ledge and remove the carrying sling.  The rolling bearing is positioned. Sliding table Vertical ledge Rolling bearing Figure 40 Positioning the rolling bearing, vertical ledge BA42 Schaeffler Technologies...

  • Page 57: Connecting The Temperature Sensor

    The temperature sensor is connected and attached and the temperature can be measured. Inner ring of rolling bearing Sensor head of temperature sensor Cable of temperature sensor Socket for temperature sensor Plug of temperature sensor Figure 41 Connecting and attaching the temperature sensor Schaeffler Technologies BA42...
  • Page 58 Inner ring of rolling bearing Sensor head on inner ring Cable of temperature sensor Socket for temperature sensor Plug of temperature sensor Outer ring of rolling bearing Sensor head on outer ring Figure 42 Connecting and attaching the temperature sensor BA42 Schaeffler Technologies...

  • Page 59: Selecting The Heating Method

    The screen with the values for this heating method (in this case the heating temperature) will be displayed, Figure 43. T1: 23 [°C] T1: 23 [°C] 1:34 PM 1:34 PM 16.03.2019 16.03.2019 HEATER100 Temperature control Symbol [ Set heating temperature Figure 43 [°C] [°C] Setting Schaeffler Technologies BA42...

  • Page 60: Setting Values

    Symbol [Apply] Symbol [Cancel] [°C] [°C] Figure 44 Heating temperature screen Serious injuries due to destroyed heating device with heating of the WARNING component to more than +240 °C.  Restrict the heating temperature to +240 °C. BA42 Schaeffler Technologies...

  • Page 61: Heating

    Figure 45 Countdown  Wait for the end of the countdown time.  The temperature will be displayed, the electromagnetic field will be generated and the heating operation will start.  Wait until the temperature is reached. Schaeffler Technologies BA42...

  • Page 62: Cancelling Temperature Hold

    ] to end temperature hold. The heated rolling bearing can be removed. Heating operation ended. Heating operation ended. Cancel temperature hold Cancel temperature hold Symbol Heating operation ended using START/STOP. using START/STOP. Figure 46 Heating operation ended BA42 Schaeffler Technologies...

  • Page 63: Removing The Temperature Sensor

    Where necessary, pull the plug of the temperature sensor out of the socket. Inner ring of rolling bearing Sensor head of temperature sensor Cable of temperature sensor Socket for temperature sensor Plug of temperature sensor Figure 47 Removing the temperature sensor Schaeffler Technologies BA42...

  • Page 64: Removing The Rolling Bearing

    Remove the support ledge from the rolling bearing and lay both down separately.  The rolling bearing can now be mounted. Rolling bearing Support ledge U-shaped core Figure 48 Removing the suspended rolling bearing from the support ledge BA42 Schaeffler Technologies...
  • Page 65 U-shaped core.  Slide the rolling bearing off the slewing ledge.  The rolling bearing can now be mounted. Rolling bearing Slewing ledge U-shaped core Figure 49 Removing the suspended rolling bearing from the slewing ledge Schaeffler Technologies BA42...
  • Page 66  Rotate the slewing ledge away from the U-shaped core.  Remove the rolling bearing.  The rolling bearing can now be mounted. Rolling bearing Slewing ledge U-shaped core Figure 50 Removing the rolling bearing lying flat BA42 Schaeffler Technologies...
  • Page 67  Lower the vertical ledge.  Lift the rolling bearing off the sliding table.  The rolling bearing can now be mounted. Sliding table Vertical ledge Rolling bearing Figure 51 Removing the rolling bearing Schaeffler Technologies BA42...

  • Page 68: Saving The Heating Curve

    USB stick. [°C] [°C] 16.03.2017 16.03.2017 13:38 13:38 =18K =18K Save heating curve Save heating curve 00:45:00 03:00:00 File: File: Symbol [ Save file 2017_03_16_13h_38min_43s_ 2017_03_16_13h_38min_43s_ Symbol [ Apply H200_000001.csv H200_000001.csv Figure 53 Saving the heating curve BA42 Schaeffler Technologies...

  • Page 69: Troubleshooting

    Check sensor head (seating), Check sensor head (seating), cable (broken cable) and plug (seating). cable (broken cable) and plug (seating). Customer support: Customer support: Error number support.is@schaeffler.com support.is@schaeffler.com +49 2407 9149-66 +49 2407 9149-66 Figure 54 Slight error, grey background Schaeffler Technologies BA42...

  • Page 70: Serious Error

    Some errors are displayed in a window with a red background, Figure 55. These errors cannot be remedied by the user.  Make a note of the error number.  Contact Customer Service at Schaeffler Technologies AG & Co. KG. E231 E231 Contact the customer support Contact the customer support...

  • Page 71: Maintenance

    Heating device Clean with a soft, dry cloth ■ Contact surfaces Cleaning of contact surfaces on U-shaped core ■ For optimum contact and to prevent corrosion, regularly grease with an acid-free grease, see label LUBRICATE CONTACT SURFACES Schaeffler Technologies BA42...

  • Page 72: Decommissioning

     Fit the cover to the heating device. Disposal The device can be returned to Schaeffler for disposal. The heating device can be dismantled in order to dispose of the subassemblies separately. The heating device may only be dismantled by an electrician.

  • Page 73: Heater25

    14 14 200 HEATER50.LEDGE-35 25 24 200 Adapter posts HEATER50.ADAPTER-75 40 50 75 – Suitable for rolling bearings with minimum inside diameter as stated. Designation deviates from the naming system as the component is also used for HEATER50. Schaeffler Technologies BA42...

  • Page 74: Heater50

    Dimension Mass Support ledge HEATER50.LEDGE-10 7 7 200 HEATER50.LEDGE-15 10 10 200 HEATER50.LEDGE-20 14 14 200 HEATER50.LEDGE-35 25 24 200 Adapter posts HEATER50.ADAPTER-75 40 50 75 – Suitable for rolling bearings with minimum inside diameter as stated. BA42 Schaeffler Technologies...

  • Page 75: Heater100

    Support ledge HEATER100.LEDGE-15 10 10 280 HEATER100.LEDGE-20 14 14 280 HEATER100.LEDGE-35 25 24 280 Slewing ledge HEATER100.LEDGE-55 40 38 280 Adapter posts HEATER100.ADAPTER-120 50 62 120 – Suitable for rolling bearings with minimum inside diameter as stated. Schaeffler Technologies BA42...

  • Page 76: Heater200

    20 20 350 HEATER200.LEDGE-40 30 26 350 HEATER200.LEDGE-55 40 38 350 HEATER200.LEDGE-70 50 48 350 HEATER200.LEDGE-85 60 60 350 10,4 Adapter posts HEATER200.ADAPTER-150 70 80 150 – 11,4 Suitable for rolling bearings with minimum inside diameter as stated. BA42 Schaeffler Technologies...

  • Page 77: Heater400

    20 32 490 HEATER400.LEDGE-50 30 38 490 HEATER400.LEDGE-65 40 50 490 HEATER400.LEDGE-80 50 60 490 80 12,8 HEATER400.LEDGE-90 60 72 490 90 17,4 HEATER400.LEDGE-105 70 82 490 105 22,6 Suitable for rolling bearings with minimum inside diameter as stated. Schaeffler Technologies BA42...

  • Page 78: Heater800

    50 60 750 80 18,3 HEATER800.LEDGE-90 60 72 750 90 25,4 HEATER800.LEDGE-105 70 82 750 105 33,8 HEATER800.LEDGE-120 80 92 750 120 43,3 HEATER800.LEDGE-135 90 102 750 135 54 Suitable for rolling bearings with minimum inside diameter as stated. BA42 Schaeffler Technologies...

  • Page 79: Heater1600

    60 72 1 080 90 36,6 HEATER1600.LEDGE-120 80 92 1 080 120 62,4 HEATER1600.LEDGE-150 100 112 1 080 150 94,9 Suitable for rolling bearings with minimum inside diameter as stated. Original accessories Only use FAG original accessories. Schaeffler Technologies BA42...

  • Page 80: Appendix Eu Declaration Of Conformity

    Induction heating devices HEATER Appendix This appendix contains the Declaration of Conformity for heating devices. EC Declaration of Conformity Declaration of Conformity for heating devices HEATER25, HEATER50, HEATER100, HEATER200, HEATER400, HEATER800 and HEATER1600, Figure 56. Figure 56 Declaration of Conformity BA42 Schaeffler Technologies...
  • Page 82 Germany We reserve the right to make technical Georg-Schäfer-Straße 30 changes. 97421 Schweinfurt © Schaeffler Technologies AG & Co. KG Germany Issued: 2019, December Phone +49 2407 9149-66 This publication or parts thereof may not +49 2407 9149-59 be reproduced without our permission.

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