Schaeffler HEATER50 User Manual

Induction heating devices

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Induction heating devices

Heater SMART

User Manual

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Summary of Contents for Schaeffler HEATER50

Page 1 Induction heating devices Heater SMART User Manual...
Page 3 Temperature sensors..........................16 Control panel and connections........................18 Touchscreen..............................19 System settings............................19 4.5.1 System settings, window 1....................... 20 4.5.2 System settings, window 2....................... 21 4.5.3 System settings, window 3....................... 22 4.5.4 System settings, window 4....................... 22 Schaeffler BA 75 | 3...
Page 4 Heating in temperature mode or time mode................ 59 7.8.4 Heating in temperature mode and speed mode ..............61 Mounting the workpiece ..........................64 Troubleshooting ............................... 65 Adjusting the slewing yoke ........................65 Adjusting the vertical yoke ......................... 66 Error messages............................67 4 | BA 75 Schaeffler...
Page 5 13.7 HEATER400-SMART............................80 13.8 HEATER600-SMART............................81 13.9 HEATER800-SMART............................82 13.10 HEATER1600-SMART............................ 83 13.11 Cable colours..............................84 13.11.1 HEATER50 to HEATER150 ......................84 13.11.2 HEATER200 to HEATER1600 ..................... 84 13.12 Declaration of Conformity.......................... 85 14 Accessories ................................87 Schaeffler BA 75 | 5...
Page 6 Heavy load warning Floor-level obstacle warning Prohibited for persons with pacemakers or implanted defibrillators Prohibited for persons with metallic implants Carrying of metallic parts or watches prohibited Carrying of magnetic or electronic data carriers prohibited Observe the manual 6 | BA 75 Schaeffler...
Page 7 1.6 Further information | The selection wizard in medias can assist in the selection of a suitable heating device: https://www.schaeffler.de/std/1FEA. Address any questions on fitting to your local contact at Schaeffler. Schaeffler BA 75 | 7...
Page 8 The power cable must be checked for damage prior to every use. The device must always be safely disconnected from the mains before undergoing maintenance or repair work. This is achieved by removing the mains plug from the socket. 8 | BA 75 Schaeffler...
Page 9 • implantable defibrillator (ICD) • stent • hip implant • knee implant • metal plate • metal screw • dental implant and dentures • cochlear implant • neurostimulator • insulin pump • hand prosthesis • subcutaneous piercing Schaeffler BA 75 | 9...
Page 10 Some heating devices weigh more than 23 kg and should not be lifted by just one person. 2.4.6 Falling objects | Users must wear safety shoes to prevent foot injuries caused by falling work- pieces or machine parts. 10 | BA 75 Schaeffler...
Page 11 The heating device must be stored under the following ambient conditions: • humidity min. 5 %, max. 90 %, non-condensing • protected against sunlight and UV radiation • no explosion risk in the environment • no aggressive chemicals in the environment • temperature from 0 °C (+32 °F) to +50 °C (+122 °F) Schaeffler BA 75 | 11...
Page 12 The support, slewing or vertical yoke must never be removed during the heat- ing process. The heating device must not be switched off using the main switch while the device is heating a component. 12 | BA 75 Schaeffler...
Page 13 Only an electrician is in a position, on the basis of his technical training, knowl- edge and experience as well as his knowledge of the appropriate regulations, to carry out work on electrical devices correctly and recognise possible haz- ards. Schaeffler BA 75 | 13...
Page 14 3.2 Defects | 1. Check the product immediately upon delivery for visible defects. 2. Report any defects promptly as a complaint to the distributor of the prod- uct. 3. Damaged products should not be used. 14 | BA 75 Schaeffler...
Page 15 The electromagnetic field decreases within a distance of 1 m to such an extent that it is below the applicable standard value of 0,5 mT. q1 Function 001A366C Primary coil Secondary coil, in this case a rolling bearing U-shaped iron core Yoke Electromagnetic field Schaeffler BA 75 | 15...
Page 16 | The magnetic temperature sensors are included in the scope of delivery and are available to reorder u87|14. Special clamping sensors are available by agreement from Schaeffler for non- ferromagnetic workpieces. Design • The temperature sensor is equipped with a magnetic clamp for easy attach- ment to the workpiece.
Page 17 Appearance of measurement values on the display: • measured value at T1: red • measured value at T2: green Do not pull the temperature sensor by the cable when removing it from the temperature sensor. Pull on the plug and sensor head only. Schaeffler BA 75 | 17...
Page 18 Starts and stops the heating process q5 Connections 001B249D Sensor connection T1 for temperature Sensor connection T2 for temperature sensor 1 (main sensor) sensor 2 USB connection for logging heating data 18 | BA 75 Schaeffler...
Page 19 4.5 System settings | The heating device allows parameters to be set and adjusted according to the requirements of the heating process. ▸ Tap [System settings] to access the settings. » The [System settings] window opens. Schaeffler BA 75 | 19...
Page 20 • The settings are protected by a password. • The settings are not available at user level and, as a result, are not access- ible to the user. 4.5.1 System settings, window 1 | q7 [System settings], screen 1 001ABF26 20 | BA 75 Schaeffler...
Page 21 4.5.2 System settings, window 2 | q8 [System settings], window 2 001ABF46 e8 Setting options Field Setting option [Default Temperature Hold] Activate or deactivate to maintain the standard tempera- ture. Schaeffler BA 75 | 21...
Page 22 Set unit for temperature measurement value: °C or °F. [Language] Set display language. • English • German • French • Italian • Dutch • Spanish 4.5.4 System settings, window 4 | q10 [System settings], window 4 001ABF86 22 | BA 75 Schaeffler...
Page 23 4.5.5 System settings, window 5 | q11 [System settings], window 5 001ABFA6 e11 Setting options Field Setting option [System Date and Time] Set system date and system time. [Enable ΔT] Activate Delta T function, if required. Schaeffler BA 75 | 23...
Page 24 ΔT being exceeded. [ΔT timeout] Time (min:s) within which a restart is possible after ΔT has been exceeded. [ΔT switch off temperature] Temperature difference between two measurement points on a workpiece at which heating is stopped. 24 | BA 75 Schaeffler...
Page 25 • No temperature sensor required as the temperature is not monitored. • If 1 or more temperature sensors are connected, the workpiece tempera- ture is displayed but not monitored. • After the heating process, the workpiece is demagnetised. Schaeffler BA 75 | 25...
Page 26 Example: Workpiece is heated to +120 °C at a rate of increase of 5 °C/min. • Heating of the workpiece to the set temperature. • Monitoring of the workpiece temperature throughout the entire process. • Choice of simple measurement and Delta T measurement under [System settings]. 26 | BA 75 Schaeffler...
Page 27 Temperature mode and speed mode will only be executed correctly if the rate of increase is set at a realistic value and is proportional to the maximum power that the heating device can deliver and transmit to the workpiece. Schaeffler BA 75 | 27...
Page 28 2. Press [Start]. › An input window opens for entering the log information. 3. Heating cannot start until all information has been entered. 4. Enter the operator name [Operator name] and the name of the workpiece [Workpiece data]. 28 | BA 75 Schaeffler...
Page 29 An input keyboard will appear. q15 Entering information for the log 001AAD5F 6. Enter the required information. 7. Press [Enter] to complete the entry. › The keyboard is hidden. › The inputted data is transferred to the corresponding field. Schaeffler BA 75 | 29...
Page 30 The log is stored as a PDF diagram and CSV file on the USB storage device. It is not necessary to export the log file immediately after each heating cycle. The information is stored in the heating device and can be exported at a later date. 30 | BA 75 Schaeffler...
Page 31 The heating device automatically saves the following data during the heating process: e14 Automatically saved log files Log type Description [Last crash] Data obtained from the process shortly before the heating device suffered a failure (“crash”). [Heating logs] Data from the stored heating processes. [Alarms] Alarms triggered Schaeffler BA 75 | 31...
Page 32 [Heating logs] displays a list of saved heating logs. 1. Use the arrow keys to scroll through the overview. 2. To select a log, press the corresponding line. 3. Decide whether you wish to view or delete the selected log. 32 | BA 75 Schaeffler...
Page 33 The log is stored as a PDF diagram and CSV file on the USB storage device. 4. Press [Back] to return to the previous menu. 4.7.4.2 [CLEAR] | 1. Delete the selected log by pressing [CLEAR]. q21 Deleting the log file 001AC9A6 Schaeffler BA 75 | 33...
Page 34 1. Use the arrow keys to scroll through the overview. 2. To select an alarm, press the corresponding line. 3. Open the required alarm by pressing [VIEW]. › The selected alarm message is displayed. q23 Example of an alarm message 001AC9E6 34 | BA 75 Schaeffler...
Page 35 The heating device has additional functions for controlling the heating process. 4.8.1 Demagnetisation | If a heating process stops or is stopped manually, the workpiece is demagnet- ised. The following message briefly appears on the display: [Demagnetizing]. q24 Demagnetisation of the workpiece 001B13B4 Schaeffler BA 75 | 35...
Page 36 1. The length of time that a workpiece should be held at a specific tempera- ture can be set by tapping [Hold time]. The time is set in mm:ss and can be between 00:01 and 99:00. 36 | BA 75 Schaeffler...
Page 37 Once the target temperature has been reached during the heating process, the remaining temperature maintenance time is displayed on a timer. q28 Remaining temperature maintenance time 001AC066 3. Once the set time has elapsed, a message will appear on the display. Schaeffler BA 75 | 37...
Page 38 4|Product description q29 Message confirming elapsed temperature hold function period 001AC046 4. Press [OK] to close the message. › The temperature curve over time is displayed. q30 Example of temperature curve for temperature hold function 001AC926 38 | BA 75 Schaeffler...
Page 39 If the process is paused, [Delta T PAUSE] is shown on the display. 3. If [ΔT automatic restart] is not activated, heating must be restarted manu- ally. › If T1 falls below the set [ΔT switch on temperature] within the time set for [ΔT timeout], heating is started automatically. Schaeffler BA 75 | 39...
Page 40 The temperature difference must be reached within [ΔT timeout]. If the time limit is exceeded, the error message [Delta T timeout] is displayed. 4. Press [CLEAR] to close the message. q33 Error message for exceeded time limit 001AC554 40 | BA 75 Schaeffler...
Page 41 › A menu containing the current settings and actual values will open. q35 Example of a heating target 001AC594 2. Press on the value to be changed. › An input keyboard will appear. 3. Enter the new value. Schaeffler BA 75 | 41...
Page 42 4|Product description q36 Input keyboard 001AC5B4 4. Press [OK] to complete the entry. › The display will return to the heating menu. » The target value for the current heating operation has been changed. 42 | BA 75 Schaeffler...
Page 43 46 kg must be carried by 2 people if necessary. For very heavy products weighing in excess of 46 kg, a device with a sufficiently high load-carrying capacity must be used. e16 Transporting the device Device 1 person 2 people Device HEATER50 ✓ ✓ ✓ HEATER100 ✓ ✓ HEATER150 ✓...
Page 44 Attach clearly visible warning signs to alert persons fitted with implants to the hazard area. ▸ Attach clearly visible warning signs to alert persons carrying metal parts to the hazard area. q37 Hazard area 00196592 Hazard area, 1 m Barrier Flat work surface capable of supporting load 44 | BA 75 Schaeffler...
Page 45 Avoid contact between the mains connection cable and the component to be heated. 2. Lay the connection cable in such a way that it is set apart from the sub- sequent workpiece position. 3. Insert the mains connection plug into a suitable socket. Schaeffler BA 75 | 45...
Page 46 This allows the heating device to heat up more quickly and evenly. NOTICE Drops or impacts Damage to the support yoke, slewing yoke or vertical yoke ▸ Place the yoke or yokes into storage immediately after use. 46 | BA 75 Schaeffler...
Page 47 HEATER200 ✓ ✓ ✓ HEATER400 ✓ ✓ ✓ HEATER600 ✓ ✓ ✓ HEATER800 ✓ ✓ HEATER1600 ✓ ✓ ✓ possible q38 Positioning options: HEATER50 to HEATER600 001A3F8C Rolling bearing freely suspended Rolling bearing suspended Rolling bearing lying flat Schaeffler BA 75 | 47...
Page 48 Avoid damaging the slewing yoke and hinge. Large workpieces can be thermally insulated by wrapping them in insulation material (such as a welding blanket). This keeps the heat in the workpiece and prevents it from cooling as quickly. 48 | BA 75 Schaeffler...
Page 49 7.4.3 Workpiece in a suspended position | With all tabletop devices, there is the option to heat the workpiece while it is suspended from a support yoke or slewing yoke. Schaeffler BA 75 | 49...
Page 50 ▸ Observe the maximum permissible mass of the workpiece. e18 Maximum mass of the workpiece, limited by the load carrying capacity of the yoke Heating device Support yoke, slewing yoke Workpiece Maximum mass HEATER50 7×7×200 10×10×200 14×14×200 20×20×200 40×40×200 40×50×200 HEATER100 10×10×280...
Page 51 4. Slide the workpiece over the slewing yoke until the workpiece is in the middle. q42 Suspended from the slewing yoke 001A3F1C 5. Swivel the slewing yoke back to the U-shaped core. 6. Ensure that the workpiece does not come into contact with the plastic housing of the heating device. Schaeffler BA 75 | 51...
Page 52 In the case of a rolling bearing, for example, this will be on the outer ring. » The temperature sensors are ready for operation. After use, attach the temperature sensor to the U-shaped core, as close as possible to the control panel. 52 | BA 75 Schaeffler...
Page 53 Switch on the heating device using the main switch. › The heating device will commence the startup operation. › The startup operation takes some time to complete, ~20 s. › A loading screen is displayed whilst the startup operation is in progress. q44 Loading screen 001A5244 Schaeffler BA 75 | 53...
Page 54 The maximum rate at which the temperature increases per unit of time can be entered so that the work- piece is heated along a specified curve. The temperature hold function is avail- able for use. 54 | BA 75 Schaeffler...
Page 55 2. Touch [Temperature] and set the target temperature for the heating oper- ation. 3. Activate the [Temp. Hold] selector switch and set the desired hold time if the temperature hold function is required. 4. Activate the [Logging] selector switch if logging of the heating operation is required. Schaeffler BA 75 | 55...
Page 56 001ACFED q48 Expanded data overview 001AD00D 6. Press [Additional information] to toggle between a graphic representation and an expanded data overview. » Once the workpiece has reached the target temperature, a loud beep will sound. 56 | BA 75 Schaeffler...
Page 57 If a temperature sensor is attached, its temperature will be shown on the display. › If a second temperature sensor T2 is attached, its temperature will also be shown on the display. In time mode, the measured temperatures have no effect on the process. Schaeffler BA 75 | 57...
Page 58 The heating device will switch off automatically once the set time has elapsed. A loud beep will sound. 6. To cancel the beep, press [Stop]. » The heating process has finished. The workpiece is demagnetised. The heating operation can be terminated at any time by pressing [Stop]. 58 | BA 75 Schaeffler...
Page 59 The display shows the time remaining for the process. › The display shows the current workpiece temperature at temperature sensor T1. › If a second temperature sensor T2 is attached, its temperature will also be shown on the display. Schaeffler BA 75 | 59...
Page 60 A loud beep will sound. 7. To cancel the beep, press [Stop]. » The heating process has finished. The workpiece is demagnetised. The heating operation can be terminated at any time by pressing [Stop]. 60 | BA 75 Schaeffler...
Page 61 6. Press [Start] to start the heating operation. › The heating operation will commence. › The display shows the current workpiece temperature at temperature sensor T1. › If a second temperature sensor T2 is attached, its temperature will also be shown on the display. Schaeffler BA 75 | 61...
Page 62 7|Operation q56 Display of the heating process in temperature mode and speed mode 001AD10D q57 Graphic representation 001B11AB q58 Expanded data overview 001AD00D 62 | BA 75 Schaeffler...
Page 63 A message will appear and a loud continuous beep will sound once the set time has elapsed. 8. To cancel the beep, press [Stop]. » The heating process has finished. The workpiece is demagnetised. The heating operation can be terminated at any time by pressing [Stop]. Schaeffler BA 75 | 63...
Page 64 When using a slewing yoke: Open the slewing yoke up to the positioning cam and slide the workpiece off the slewing yoke. When using a vertical yoke: Pull the vertical yoke upwards. 3. Mount the workpiece immediately to prevent it from cooling down. 64 | BA 75 Schaeffler...
Page 65 1× 2× 180° 180° 001A4209 Hexagon socket screw 7. Switch on the device. 8. Press [Start]. › The slewing yoke will now adjust itself. 9. If necessary, tap the slewing yoke gently with a plastic hammer. Schaeffler BA 75 | 65...
Page 66 5. Switch on the device. 6. Press [Start]. › The vertical yoke will now adjust itself. 7. If necessary, tap the vertical yoke gently with a rubber hammer. 8. Tighten all screws. 9. Switch off the device. 66 | BA 75 Schaeffler...
Page 67 13. Switch off the device using the main switch. too low] °C (+14 °F). 14. Wait until the ambient temperature has risen above −10 °C (+14 °F). 15. If the temperature is within the limit value and the error still occurs, contact Schaeffler. Schaeffler BA 75 | 67...
Page 68 34. Check the mains current. been demagnetized!] 35. Switch the device on again. 36. If the problem continues, contact Schaeffler. [The coil current has exceeded its A root mean square current through 37. Switch off the device using the main switch and limit, Attention: the yoke has not the coil is too high.
Page 69 U-shaped core and yoke and to prevent corrosion. Stud Lubricate the stud regularly with petrolatum. Yoke (support yoke, slewing yoke or Adjust the yoke if strong vibrations occur u65|8.1. vertical yoke) Schaeffler BA 75 | 69...
Page 70 A repair is essential if the device shows visible signs of damage. If a fault other than strong vibrations occurs, a repair will usually be necessary. 1. Switch off the device 2. Disconnect the device from the power supply 3. Prevent the device from being used further 4. Contact the manufacturer 70 | BA 75 Schaeffler...
Page 71 The heating device should be decommissioned if it will no longer be used regu- larly. Decommissioning: 1. Switch off the heating device using the main switch. 2. Disconnect the heating device from the power supply. 3. Cover the heating device. Schaeffler BA 75 | 71...
Page 72 12|Disposal 12 Disposal | 1 2 Disposal must be carried out in accordance with locally applicable regulations. 72 | BA 75 Schaeffler...
Page 73 Standard accessories are included in the scope of delivery, special accessories can be ordered separately. Dimension-related terms are used in the tables. These terms are explained in the images. q63 Dimensions HEATER50 to HEATER200 001A4584 Maximum outside diameter of the Pole distance...
Page 74 13|Technical data q65 Dimensions HEATER800 and HEATER1600 001A4624 Maximum outside diameter of the Pole distance workpiece Pole length Pole cross-section 74 | BA 75 Schaeffler...
Page 75 The maximum mass of the workpiece refers to the heating of workpieces to +100 °C at the specified voltage supply. In the event of a higher temperature or different voltage supply, please consult your contact at Schaeffler. e25 Maximum mass and necessary power supply for a heating temperature of +100 °C...
Page 76 13|Technical data 13.3 HEATER50-SMART | The devices are designed for continuous operation. The heating time is only re- stricted at maximum heating temperature. e26 Heating device Designation Value Dimensions L×W×H 600 mm×226 mm×272 mm U-shaped core Pole distance (B) 120 mm Pole length (C) 130 mm...
Page 77 HEATER100.YOKE-30 20×20×280 0,84 ✓ e34 Slewing yokes Ordering designation Dimensions Mass Min. bore diam- Scope of eter delivery HEATER100.YOKE-45 30×30×280 HEATER100.YOKE-60 40×40×280 3,87 HEATER100.YOKE-72 50×50×280 5,78 ✓ HEATER100.YOKE-85 60×60×280 8,09 ✓ included in delivery available as an option Schaeffler BA 75 | 77...
Page 78 Dimensions Mass Min. bore diam- Scope of eter delivery HEATER200.YOKE-45 30×30×350 3,67 ✓ HEATER200.YOKE-60 40×40×350 5,51 HEATER200.YOKE-72 50×50×350 7,79 HEATER200.YOKE-85 60×60×350 10,69 HEATER200.YOKE-100 70×70×350 14,0 HEATER200.YOKE-110 70×80×350 15,90 ✓ ✓ included in delivery available as an option 78 | BA 75 Schaeffler...
Page 79 Dimensions Mass Min. bore diam- Scope of eter delivery HEATER200.YOKE-45 30×30×350 3,67 ✓ HEATER200.YOKE-60 40×40×350 5,51 HEATER200.YOKE-72 50×50×350 7,79 HEATER200.YOKE-85 60×60×350 10,69 HEATER200.YOKE-100 70×70×350 14,0 HEATER200.YOKE-110 70×80×350 15,90 ✓ ✓ included in delivery available as an option Schaeffler BA 75 | 79...
Page 80 Ordering designation Dimensions Mass Min. bore diam- Scope of eter delivery HEATER400.YOKE-30 20×20×500 3,12 HEATER400.YOKE-45 30×30×500 4,95 HEATER400.YOKE-60 40×40×500 7,55 HEATER400.YOKE-85 60×60×500 14,83 HEATER400.YOKE-115 80×80×500 25,40 ✓ ✓ included in delivery available as an option 80 | BA 75 Schaeffler...
Page 81 Outside diameter (A) max. 1050 mm e52 Slewing yokes Ordering designation Dimensions Mass Min. bore diam- Scope of eter delivery HEATER600.YOKE-60 40×40×600 8,57 HEATER600.YOKE-85 60×60×600 17,43 HEATER600.YOKE-115 80×80×600 29,10 HEATER600.YOKE-130 90×90×600 37,90 ✓ ✓ included in delivery available as an option Schaeffler BA 75 | 81...
Page 82 1150 mm e56 Vertical yokes Ordering designation Dimensions Mass Min. bore diam- Scope of eter delivery HEATER800.YOKE-60 40×40×725 HEATER800.YOKE-72 50×50×725 14,5 HEATER800.YOKE-85 60×60×725 20,3 HEATER800.YOKE-115 80×80×725 36,10 HEATER800.YOKE-145 100×100×725 56,4 ✓ ✓ included in delivery available as an option 82 | BA 75 Schaeffler...
Page 83 Outside diameter (A) max. 1700 mm e60 Vertical yokes Ordering designation Dimensions Mass Min. bore diam- Scope of eter delivery HEATER1600.YOKE-85 60×60×1140 32,5 HEATER1600.YOKE-115 80×80×1140 56,76 HEATER1600.YOKE-145 100×100×1140 88,69 HEATER1600.YOKE-215 150×150×1140 199,56 ✓ ✓ included in delivery available as an option Schaeffler BA 75 | 83...
Page 84 13|Technical data 13.11 Cable colours | The connection cables used are determined by the model. 13.11.1 HEATER50 to HEATER150 | e61 1-phase heating device 120 V/230 V Colour Assignment Brown Phase Blue Zero Green/yellow Earth e62 1-phase heating device 120 V/240 V...
Page 85 ■ EN 61000-3-11:2019 ■ EN 61000-3-12:2011 + A1:2021 + A2:2024 ■ EN 61000-3-3:2013 + A1:2021 A1:2019 + A2:2021 EMC Immunity ■ EN 61000-6-2:2019 H. van Essen Place, Date: Managing Director Vaassen, 01-07-2024 Schaeffler Smart Maintenance Tools BV Schaeffler BA 75 | 85...
Page 86 ■ EN 61000-3-11:2019 ■ EN 61000-3-12:2011 + A1:2021 + A2:2024 ■ EN 61000-3-3:2013 + A1:2021 A1:2019 + A2:2021 EMC Immunity ■ EN 61000-6-2:2019 H. van Essen Place, Date: Managing Director Vaassen, 01-07-2024 Schaeffler Smart Maintenance Tools BV 86 | BA 75 Schaeffler...
Page 87 Additional accessories are available for the heating devices, e.g.: • optional wheels • lifting equipment for vertical yokes Information on ordering accessories and further information on the heating devices can be found in the following publication: TPI 282 | Induction heating devices | https://www.schaeffler.de/std/1FE4 Schaeffler BA 75 | 87...
Page 88 Schaeffler Technologies AG & Co. KG All information has been carefully compiled and Georg-Schäfer-Straße 30 checked by us, but we cannot guarantee complete accuracy. We reserve the right to make corrections. 97421 Schweinfurt Therefore, please always check whether more Germany up-to-date or amended information is available.

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