NKE DualSense HeatPro User manual

User Manual
NKE DualSense HeatPro

Note
Check delivery for possible damage caused by transport without delay. Should
damage be detected, please inform carriers immediately.
As our products are subject to continuous improvement, we reserve the right
to make changes to this document.

INDUCTION HEATING 5
Operating conditions 5
SAFETY GUIDELINES 6
Safety precautions 7
Safety instructions 8
Safety features 9
INSTALLATION 10
Scope of delivery 10
Unboxing 10
Installation process 11
SETTING UP THE WORKPIECE 12
Choosing the yoke 13
Positioning the magnetic temperature probe(s) 14
OPERATION 15
Temperature Mode, using one sensor 16
Ramp Mode 17
Temperature Mode, using two sensors 18
Time Mode 19
User menu 20
MAINTENANCE 21
MALFUNCTION 22
Adjusting the yoke 22
Errors 23
SPECIFICATIONS 24
Dimensions 24
Workpiece dimensions 25
Technical data 26
Additional information 27
Electrical drawing 28
1
2
3
4
5
6
7
8
CONTENTS

4

5
1
NKE DualSense HeatPro induction heaters are used to heat rolling bearings. Other
metal components forming a closed circuit such as bushings, shrink rings, pulleys
and gears can also be heated. This will facilitate mounting where an interference t
is required.
Our range of standard heaters are designed to heat the workpiece to a maximum
temperature of 240ºC (464°F). Always place the temperature sensor on the
workpiece to check the heating cycle. When heating an object using Time Mode, the
heating cycle must be checked using an external temperature meter.
CAUTION
Bearings generally should only be heated to a maximum temperature of 120ºC
(248ºF). Do not use induction heaters for bearings or workpieces with dimensions
outside the ranges specied in this manual. Do not switch off the heater with the
main switch while heating cycle is running.
The heater is designed to be used in an industrial environment with an ambient
temperature of 0°C to 40°C (32°F to 104°F) and an atmospheric humidity between
5% and 90%, non-condensing. The induction heater is intended for indoor use only.
INDUCTION HEATING
OPERATING
CONDITIONS

6
SAFETY GUIDELINES
2
The operating instructions should always be followed when using an induction heater.
NKE Bearings shall not be held liable for damages caused by improper handling or
by use which does not comply with the designated purpose. Prerequisites for the
operator: He/she must be authorised for use of the heater and must be familiar with
the safety precautions.
In order to prevent danger or damage to the induction heater or workpiece, follow
these guidelines:
`All repairs must be carried out by an ofcial NKE Bearings distributor.
`Use original spare parts only.
`Protect the heater from water or very high humidity.
`Protect the heater core and yokes against corrosion, damage and deformation.
`Only preheat bearings to max. 120°C (248°F).
`To ensure proper operation of the device, it is important to provide the device
with the latest software updates. A description can be found in chapter 5 -
OPERATION, page 20 - USER MENU.

7
SAFETY
PRECAUTIONS
`Since a magnetic eld 4&5 is generated by the induction heater, people wearing
a pacemaker 1or other implant device 2should not work or be in the immediate
vicinity of the device. Other sensitive equipment such as wrist watches, magnetic
carriers, electronic circuits, etc. 3might also be affected. The safety distance is
0.5 meters (19”).
`Use protective gloves as protection against burns to hands. The gloves delivered
are suitable for use up to temperatures of 150°C (302°F).
`Hot surface, avoid contact 6.
`Do not operate an induction heater in areas where there is risk of explosion.
`Wear safety shoes 8.
1. 2. 3. 4.
8.7.
6.5.

8
`The user should have an appreciation of the contents of this user manual, and
be familiar with safe workshop practices.
`Follow the user manual at all times.
`Ensure that the induction heater operates at the correct supply voltage. If the
heater is not supplied with a plug, changes should only be made by a suitably
qualied electrician.
`Do not use or store the heater in humid environments. The heater is designed
for indoor use only.
`Use proper handling equipment, appropriate for the weight of the workpiece
and/or yoke. Never support components with a metal cable or have any hanging
in the proximity of the magnetic eld. Extremely high currents can flow through
the cable causing it to heat up quickly, resulting in a risk of burning.
`Do not place any metal objects near the yokes and poles.
`Place heater on a stable, horizontal surface.
`Keep a minimum distance of 1 meter (38”) to surrounding objects.
`Use only in well ventilated areas.
`Do not heat objects containing oil, grease or similar substances. Prevent
possible generation of fumes and smoke.
`Do not inhale fumes or smoke from heated parts.
`Do not move or lift heater when warm after heating cycle.
`Do not touch the heater core during heating cycle.
SAFETY
INSTRUCTIONS

9
Should an error occur during the heating process, the induction heater will
automatically stop. The corresponding error will be displayed on screen. In the case
of user error, the display indicates what steps are to be taken to correct the problem.
More information about the types of errors can be found in chapter 7 - ERRORS.
An induction heater produces an electromagnetic eld within a coil to transfer energy
to a workpiece. The table below shows values of the flux density in microTesla
(µT). These measurements can be used as a guide conforming to local regulations
regarding the maximum time exposure to magnetic elds. Different congurations
may give different values. It is impossible to provide
values for all combinations as the variety of bearing
types in combination with the different yokes is
large.
Total 50Hz RMS eld for magnetic measurement results. Max. magnetic flux in safe
exposure area, according to the German BG 11 Regulations is 423 µT.
SAFETY
FEATURES
MP1x 81 249 283
MP2x 16 34 74
MP3x 1 11 28
MP1y 156 181 185
MP2y 27 24 78
MP3y 9 9 41
Measurement position (cm) B-eldtotal (µT)
MP2x
60
MP1x
30
MP3x
90
30
60
90
MP1y
MP2y
MP3y
X
(cm)
Y
(cm)
MNKE DualSense HeatPro 400 500 600

10
INSTALLATION
3
SCOPE OF
DELIVERY
Contents of the box
1. NKE DualSense HeatPro 400 / 500 / 600
2. Yoke(s)
3. Temperature probes
4. Heat-resistant gloves
5. User Manual
6. Quickstart guide
Note
The NKE DualSense HeatPro 400 comes with yokes 10, 14, 25, and 40 included.
NKE DualSense HeatPro 500 includes yoke 50 and NKE DualSense HeatPro 600
includes yoke 70.
Follow the instructions specic for this heater on the supplied Quickstart guide. If
the Quickstart guide is not included in this box, please contact your distributor. The
induction heater must always be transported in the original box, thus also on return
to the manufacturer/distributor.
UNBOXING

11
Turn main switch from 0 to 1. The device will emit a short
beep and the touchscreen display will show the main
menu. The induction heater is now ready for use.
INSTALLATION
PROCESS
Ensure that supply voltage and current meet the specications. These can be found
on the type plate at the back of the induction heater.
Each induction heater is provided with a plug, but there are
a large number of plug types. Should the plug not t your
power supply, a suitable plug must be afxed by a qualied
electrician. Voltages may differ for customized devices.
Insert the plug into a shockproof wall socket and then
connect the device to mains electricity.
Phase Neutral Ground
Voltage
115V Green/YellowWhite
Black
230V Green/Yellow
BlueBrown
Phase X / L1 Phase Y / L2 Ground
Voltage
460-575V Green/Yellow
400-440V Green/Yellow
Black (USA) Black (USA)
Brown Blue
Brown
Black (USA)
Blue
Black (USA)
400 / 500
400 / 500
600
600

12
SETTING UP THE WORKPIECE
4
`Use appropriate hoisting equipment for heavy components and yokes. Manual
lifting of heavy objects is a common cause of injury.
`Wear safety shoes during these procedures.
`The weight of the work-piece should not exceed the maximum weight as shown
in chapter 8 - WORKPIECE DIMENSIONS. Exceeding these limits may result in
catastrophic equipment failure and may also lead to personal injury.
`Ensure there is no contact between the mains cable and the workpiece. Damage
to the cable may result in electrocution.
`Never support components with a metal cable and avoid metal cables hanging
in the proximity of the magnetic eld. Extremely high currents can flow through
the cable causing it to heat quickly, resulting in risk of burning.
The workpiece can be set up in two different ways and must never touch the housing.
Small objects are to be heated in a vertical position.
VERTICAL HORIZONTAL

13
`Choose largest possible yoke which ts the diameter of the workpiece. Position
the workpiece onto the yoke and place the yoke with the machine milled surface
on the poles of the heater core.
`Always make sure that the workpiece avoids direct contact with the housing of
the heater.
`When a heating cycle is completed, always wear heat-resistant gloves. The
maximum temperature of the workpiece on a standard induction heater is
240°C (464°F).
`Always treat yokes carefully. Falling, bumping, etcetera can damage the yoke
and/or cause personal injury. Always store the yoke safely immediately after use.
CHOOSING
THE YOKE

14
`Always use the magnetic temperature probe (hereafter referred to as the
‘probe’) for heating in Temperature Mode or Ramp Mode.
`Place the probe on the workpiece, close to the bore. Make sure that the surface
used for the probe is free of grease and/or oil.
`If the induction heater has two probes: place one close to the bore and the other
on the outer ring.
`Our standard probes are suitable for operation up to a maximum temperature of
240°C (464°F). The connection between magnet and probe will break above the
maximum temperature. If this occurs when operating in Temperature Mode, the
heater will turn itself off as the probe will fail
to register any increase in the temperature
over a set period of time. Probes for higher
temperatures are optional.
`Connect the probe by inserting the plug into
the socket at the front of the heater, with the
red dot facing upwards.
POSITIONING
THE MAGNETIC
TEMPERATURE
PROBE(S)
Treat the probe with care. It is a valuable part of the heater and can easily be
damaged through careless handling. After use, we suggest that it be placed on the
side of the vertical pole.
CAUTION

15
When the induction heater is turned on, the homescreen can show up to four buttons
with different modes; Time Mode is always available. Temperature Mode (with 1
sensor) and Ramp Mode will be enabled when one sensor is inserted.
An extra Temperature Mode (with 2 sensors) will be enabled when a second sensor
is inserted.
The start/stop button is used for starting heating cycles in one of the modes, or to
stop a heating cycle at any time.
When a heating cycle is complete, or stopped prematurely, the program will return
to the main screen of the heating mode. A graph can be requested with the graph
button .
Every mode has three stages:
1. Preparation - The user can change the temperature and/or time.
2. Heating process - The induction heater starts the heating cycle.
3. Completion - The heating cycle has ended.
OPERATION 5

16
Press to start the
heating cycle and stand
at a safe distance.
There is a 5 second
countdown before the
cycle starts.
When the preset
temperature has been
reached the heater will
hold that temperature.
Press to stop the
heating cycle.
The induction heater will
now demagnetize.
Hereafter it will return to
the rst screen.
Alternatively, to start the
heating process, press the
start button on the remote
control. Remote control is
sold separately.
1. PREPARATION
2. HEATING PROCESS
3. COMPLETION
Press or to change the
temperature (max. 240°C).
To change the
temperature press A, to
change the max. power
output press B.
Otherwise proceed to
step 2.
Press when the temperature
is set.
TEMPERATURE MODE, ONE SENSOR
Press or to change
the max. power output.
Press when the max. power
output is set.
A
B

17
Press to start the
heating cycle and stand
at a safe distance.
There is a 5 second
countdown before the
cycle starts.
When the preset
temperature has been
reached the heater will
hold that temperature.
Press to stop the
heating cycle.
The induction heater will
now demagnetize.
Hereafter it will return to
the rst screen.
Alternatively, to start the
heating process, press the
start button on the remote.
Remote control is sold
separately.
1. PREPARATION
2. HEATING PROCESS
3. COMPLETION
Press or to change the
temperature (max. 240°C).
Press or to
change the time.
To change the
temperature press A, to
change the heating time
press B.
Otherwise proceed to
step 2.
Press when the temperature
is set.
Press when the time is set.
RAMP MODE
A
B

18
Press to start the
heating cycle and stand
at a safe distance.
There is a 5 second
countdown before the
cycle starts.
When the preset
temperature has been
reached the heater will
hold that temperature.
Press to stop the
heating cycle.
The induction heater will
now demagnetize.
Hereafter it will return to
the rst screen.
Alternatively, to start the
heating process, press the
start button on the remote.
Remote control is sold
separately.
1. PREPARATION
2. HEATING PROCESS
3. COMPLETION
Press or to change the
temperature (max. 240°C).
Press or to change
the Δtemperature.
To change the
temperature press A
To change the Δ
temperature press B.
Otherwise proceed
to step 2.
Press when the temperature
is set.
Press when the temperature
is set.
35
35
TEMPERATURE MODE, TWO SENSORS
A
B

19
Press to start the
heating cycle and stand
at a safe distance.
There is a 5 second
countdown before the
cycle starts.
Press to stop the
heating cycle.
The induction heater will
now demagnetize.
Hereafter it will return to
the rst screen.
Alternatively, to start the
heating process, press the
start button on the remote.
Remote control is sold
separately.
TIME MODE
1. PREPARATION
2. HEATING PROCESS
3. COMPLETION
Press or to change
the time (max. 99:59).
To change the heating
time press A.
To change the max.
power output press B.
Otherwise proceed to
step 2.
Press when the time
is set.
Press or to change
the max. power output.
Press when the max. power
output is set.
A
B

20
USER MENU The user menu can be accessed by pressing the start/stop button for 8 seconds.
Within this menu the user can view and/or change the following settings:
Calibration Sensor 1
The temperature of sensor 1 can be set if it
is calibrated incorrectly.
Calibration Sensor 2
The temperature of sensor 2 can be set if it
is calibrated incorrectly.
Start Delay (5)
When the user starts the heating process
there will be able to get to a safe distance.
The factory set delay is 5 seconds.
Date Format (DD/MM)
The Date Format can be set to Day/Month or
Month/Day.
Screensaver (0)
The settings for the screen saver can be
set here, ranging from off (0) to a certain
number of minutes.
Time (HH:MM)
The current time can be set here. This
information will be used when datalogging
the heating cycle.
Date (MM/DD)
The current date can be set here. This
information will be used when datalogging
the heating cycle.
Year (YYYY)
The current year can be set here. This
information will be used when datalogging
the heating cycle.
Time Format (24:00)
The Time Format can be set to 24:00 or AM/
PM.
Temp. Hold Hysteresis (5°F)
The max. temperature difference before the
heater starts heating again can be set here.
Auto Sensor Select (On)
When this setting is turned on the heater
can recognize the difference between
Sensor 1 and Sensor 2 and assign the order
automatically.
Time Range (MM:SS)
The Time Range can be switched between
MM:SS (minutes and seconds) and HH:MM
(hours and minutes). This Time Range
setting will be applied to the available
range when using Time Mode.
Exit (Discard Changes)
Any recent adjustments will
be discarded and the user returns to the
homescreen.
Update Firmware GUI
When a USB drive (containing an update
for the User Interface) is inserted this
option will show. Press and follow the on-
screen instructions to update the heater.
Update Firmware PWR
When a USB drive (containing an update
for the Powerboard) is inserted this option
will show. Press and follow the on-screen
instructions to update the heater.
Update Languages
When a USB drive (containing an update
for texts) is inserted this option will show.
Press and follow the on-screen instructions
to update the Fonts and Texts.
Cur. Version GUI
The current version of the User Interface is
shown here.
Cur. Version PWR
The current version of the Powerboard is
shown here.
Number of Cycles
The Number of Cycles shows the amount
of heating cycles for the induction heater.
Heating Timer
The Service Counter shows the total time
(all heating cycles added together) for the
induction heater.
Reset to Factory Settings
Each user setting will be reset
to its original factory values.
Languages
The languages of the heater can be changed
to English, Spanish, German, and French.
Default Temperature (230°F)
The default temperature can be set. The
factory set temperature
is 110°C (230°F).
Temp. Hold (On)
Temperature hold can be turned on or off.
During pendulation the heater will heat to
the set temperature and cools down by 3°C,
then heats again to the set temperature, etc.
Temp. Hold Duration (5:00)
The duration of the temperature hold can be
set. With the factory set duration of 5:00 min
the heater pendulates indenitely.
Completion Signal (On)
The buzzer can be turned on or off. When
on the heater will buzz when it reaches the
set temperature. The factory set value is ‘on’.
Temperature Unit (°F)
The temperature unit can be changed
to Celsius or Fahrenheit. The factory set
temperature unit is Celsius, Fahrenheit in
the USA.
Maximum Temp. Delta (90°F)
The maximum adjustable temperature
difference between the two sensors can
be set.
Remote Control (Off)
The remote control function can be turned
on or off. Remote control is sold separately.
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