PRÜFTECHNIK EDDYTHERM User manual
EDDYTHERM operating manual
1
EDDYTHERM operating manual
Dear customer,
Thank you for choosing a PRÜFTECHNIK product. We are convinced you will be happy
with your decision. If you have any suggestions for improvement – regarding this
product or manual – please drop us a line.
PRÜFTECHNIK Alignment Systems GmbH
Freisinger Str. 34
85737 Ismaning
Germany
Tel +49 89 99616-0
Fax: +49 89 99616-100
www.pruftechnik.com
Edition January 2011
Order number ALI 9.392.G
EDDYTHERM operating manual
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EDDYTHERM operating manual
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Table of contents
Preface ................................................................5
Safety precautions and operating notes .....................................7
Safety precautions ................................................................................................................ 8
Operating notes..................................................................................................................10
EDDYTHERM 1x / EDDYTHERM 1-6 ........................................11
EDDYTHERM 4x ........................................................12
EDDYTHERM control panel ...............................................13
Brief description of operating modes and functions............................................................. 13
Starting EDDYTHERM ...................................................14
Mounting the workpiece..................................................................................................... 15
EDDYTHERM 4x swivel crossbar ..........................................................................................17
Temperature probe .............................................................................................................19
Description of operating modes and functions...............................21
Temperature shutoff............................................................................................................22
Temperature hold................................................................................................................23
Timed shutoff .....................................................................................................................24
Demagnetization ................................................................................................................25
Reduced-power heating option...........................................................................................26
Faults and error messages................................................27
Troubleshooting.................................................................................................................. 28
Crossbars............................................................................................................................29
Technical data .........................................................30
Index .................................................................31
EDDYTHERM operating manual
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EDDYTHERM operating manual
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Preface
Congratulations on your decision to purchase the EDDYTHERM induction heater. PRÜFTECHNIK has been developing
and distributing induction heaters for more than 25 years. On the basis of this extensive experience, PRÜFTECHNIK
offers induction heating technology for a broad spectrum of components: roller bearings, bushings, couplings, rolls,
gear wheels, etc. Our equipment can be used to heat small and large components for shrink fitting.
Advantages of EDDYTHERM induction heaters
Rapid, gentle and continuous heating process
Safe heating process: only the workpiece is heated
No hot oil bath, no risk of overheating
Usable with sealed roller bearings
Environmental advantages: quiet, odorless, clean, optimal energy efficiency
No deformation of workpieces
These are but a few of the many advantages of these units. If you have ideas and suggestions, please let us know –
we will do our best to incorporate your requirements in future versions! If you would like to learn more about how
the EDDYTHERM works, simply contact your PRÜFTECHNIK representative.
We wish you success with your new induction heater.
PRÜFTECHNIK Alignment Systems
January 2011
Ismaning, Germany
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EDDYTHERM operating manual
7
Safety precautions and operating notes
For some customers, EDDYTHERM will be the first induction heater they have worked with. The following information
will familiarize you with the main features of the device. In particular, you should read the safety precautions carefully
and make sure you understand them.
Intended use
EDDYTHERM is only intended for use as a heating device in industrial applications. It is designed for the inductive
heating of components, such as ball bearings, for shrink fitting. The device and its accessories should only be
operated by personnel trained in their use. PRÜFTECHNIK Alignment Systems GmbH cannot be held liable for
damages resulting from improper use.
Symbols in these instructions
The following symbols are used in these operating instructions to draw your attention to important sections. These
sections point out possible sources of danger, or provide useful information on how to operate the equipment.
This symbol alerts you of the risk of electric shocks.
This symbol alerts you to danger that may result in personal injury.
This symbol alerts you to danger arising from incorrect operation that may lead to property damage.
This symbol alerts you to hot surfaces.
This symbol alerts you to magnetic fields.
The device may only be used by operators without heart pacemakers or similar implants that are sensitive to
electromagnetic fields.
Wrist watches may be affected by magnetization.
This symbol indicates that protective gloves should be worn.
This symbol indicate that protective clothing should be worn.
This symbol indicates that the operating instructions should be read carefully.
This s
y
mbol alerts
y
ou of the risk of electric shocks
.
T
h
is s
y
m
b
o
l
a
l
erts
y
ou to
d
an
g
er t
h
at ma
y
resu
l
t in persona
l
in
j
ur
y.
This symbol alerts you to danger arising from incorrect operation that may lead to property damage
.
This s
y
mbol alerts
y
ou to hot surfaces
.
This s
y
mbol alerts
y
ou to ma
g
netic fields
.
T
h
e
d
evice ma
y
on
ly
b
e use
d
by
operators wit
h
out
h
eart pacema
k
ers or simi
l
ar imp
l
ants t
h
at are sensitive to
electromagnetic
fi
elds
.
Wrist watches ma
y
be affected b
y
ma
g
netization
.
This symbol indicates that protective gloves should be worn
.
This s
y
mbol indicate that protective clothin
g
should be worn
.
This s
y
mbol indicates that the operatin
g
instructions should be read carefull
y.
EDDYTHERM operating manual
8
These general instructions provide information and tips on operating the EDDYTHERM.
Numbers in red circles indicate the operating steps described in these instructions.
They must be performed in the order indicated.
This symbol indicates the connector for the temperature probe.
CE conformity and EMC
All versions of EDDYTHERM are in compliance with the EU Low Voltage Directive (2006/95/EC), the Electromagnetic
Compatibility Directive (EMC) (2004/108//EC), and the Machinery Directive (2006/42/EC):
EN 61000-6-1:2005-02; IEC 77/294/FDIS:2004
EN 61000-6-3:2005-06; IEC 61000-6-3:1996; VDE 0839-6-3:2005-06
EN 60519-1:2003
EN 60519-3:2005
IP classification
EDDYTHERM 1x and EDDYTHERM 1-6 have the protection class IP22 (protected against penetration by objects with
a diameter greater than 12.5 mm, protection against dripping water).
EDDYTHERM 4x has the protection class IP20 (protected against penetration by objects with a diameter greater than
12.5 mm, no protection against water).
Safety precautions
Erecting the heater
Only erect the device on a level, firm and suitable surface.
The minimum load carrying capacity of the surface must be ensured.
Do not move the device while it is loaded.
Only operate the device if the mounting columns and crossbars are undamaged.
The mounting columns and crossbar must be clean, free of corrosion and level.
The maximum weight of the workpiece must be defined.
Comply with the material type and processing temperature specifications for the workpiece.
Do not store flammable materials in the vicinity of the device.
Only operate the device with the voltage and current type specified on the type label. Only connect the
device to a properly installed power supply. An overvoltage protection device must be integrated in the
power supply.
Protect the heater against moisture.
The device and the various controls should be easily accessible.
1
These general instructions provide information and tips on operating the EDDYTHERM
.
N
umbers in red circles indicate the operatin
g
steps described in these instructions.
They must be per
f
ormed in the order indicated
.
This symbol indicates the connector for the temperature probe.
EDDYTHERM operating manual
9
Before setting up
Read the operating instructions carefully and familiarize yourself with the controls.
The equipment may only be operated and serviced by trained personnel.
The operating instructions are an integral part of EDDYTHERM and must be always be legible, complete
and available to anyone working with the device.
The device may only be used as intended and only if it is fully operational.
Disconnect the device from the power supply if damage is visible on the housing or power cord. In this
case, do not use the device.
Only start up the device in enclosed areas.
The device must be monitored at all times during operation. When the device is not used for lengthy
periods, disconnect it from the power supply.
Do not operate the device with the housing open or removed. Before opening the device, disconnect it
from the power supply.
The components being heated must be free of scale and burrs.
Magnetic field
The operation of induction heaters is always accompanied by strong magnetic fields. This must be taken into
consideration when working with the equipment. For example, wrist watches or heart pacemakers may be
influenced by the magnetic field. The device may only be used by operators without heart pacemakers or
similar implants that are sensitive to electromagnetic fields.
Do not wear metal rings on your fingers.
In order to comply with the exposure limits according to Directive 2004/40/EC, machine operating personnel
must maintain a minimum distance of 1 m in all directions as soon as the heating process begins.
Loading/unloading
Only load and unload workpieces while wearing heat-resistant work gloves.
Use suitable transport equipment and installation tools.
Wear protective clothing when loading/unloading the equipment.
Only load and unload heavy workpieces using suitable lifting gear.
Heavy workpieces may be placed on the crossbar swivel only when its locked in position.
Cleaning/maintenance
The device must be checked regularly for safe operation according to the statutory regulations of the
country in which it is used.
Repairs on the EDDYTHERM system may only be performed by factory authorized technicians.
Improper repair can lead to a significant danger to the user.
Only use original spare parts and original accessories.
The manufacturer shall not assume liability if modifications are made on the system that were not first
agreed on by the manufacturer.
Clean the device with suitable cleaning agents only (e.g., WD40 is recommended).
Grease the columns and crossbars regularly, but ensure contact surfaces between columns and crossbar
are free of grease and dirt.
Disposal
The device must be disposed of properly and in accordance with statutory regulations (Electrical and
Electronic Equipment Act).
Before setting up
Read the operating instructions carefully and familiarize yourself with the controls.
The equipment may only be operated and serviced by trained personnel
.
The operating instructions are an integral part of EDDYTHERM and must be always be legible, complete
and available to anyone working with the device
.
The device may only be used as intended and only i
f
it is
f
ully operational
.
Disconnect the device
f
rom the power supply i
f
damage is visible on the housing or power cord. In this
case, do not use the device
.
Only start up the device in enclosed areas
.
The device must be monitored at all times during operation. When the device is not used for lengthy
periods, disconnect it
f
rom the power supply
.
Do not operate the device with the housing open or removed. Before opening the device, disconnect it
f
rom the power supply
.
The components bein
g
heated must be free of scale and burrs
.
Magnetic field
The operation of induction heaters is alwa
y
s accompanied b
y
stron
g
ma
g
netic fields. This must be taken into
consi
d
eration w
h
en wor
k
in
g
wit
h
t
h
e equipment. For examp
l
e, wrist watc
h
es or
h
eart pacema
k
ers ma
y
b
e
in
fl
uenced b
y
the ma
g
netic
fi
eld. The device ma
y
onl
y
be used b
y
operators without heart pacemakers or
similar implants that are sensitive to electroma
g
netic
fi
elds
.
Do not wear metal rin
g
s on
y
our
fi
n
g
ers
.
In order to compl
y
with the exposure limits accordin
g
to Directive 2004/40/EC, machine operatin
g
personnel
m
ust maintain a minimum distance o
f
1 m in all directions as soon as the heatin
g
process be
g
ins
.
Loa
d
ing/un
l
oa
d
in
g
On
l
y
l
oa
d
an
d
un
l
oa
d
wor
k
pieces w
h
i
l
e wearing
h
eat-resistant wor
k
g
l
oves
.
Use suitable trans
p
ort e
q
ui
p
ment and installation tools
.
Wear protective c
l
ot
h
in
g
w
h
en
l
oa
d
in
g
/un
l
oa
d
in
g
t
h
e equipment
.
Onl
y
load and unload heav
y
workpieces usin
g
suitable liftin
g
g
ear
.
Heav
y
wor
k
pieces ma
y
b
e p
l
ace
d
on t
h
e cross
b
ar swive
l
on
ly
w
h
en its
l
oc
k
e
d
in position.
C
l
eanin
g
/maintenanc
e
The device must be checked re
g
ularl
y
for safe operation accordin
g
to the statutor
y
re
g
ulations of the
countr
y
in which it is used.
Repairs on the EDDYTHERM system may only be performed by factory authorized technicians
.
Improper repair can lead to a si
g
nificant dan
g
er to the user
.
On
ly
use ori
g
ina
l
spare parts an
d
ori
g
ina
l
accessories
.
The manufacturer shall not assume liabilit
y
if modifications are made on the s
y
stem that were not first
a
g
reed on b
y
the manufacturer
.
Clean the device with suitable cleanin
g
a
g
ents onl
y
(e.
g
., WD40 is recommended)
.
Grease the columns and crossbars re
g
ularl
y
, but ensure contact surfaces between columns and crossbar
are free of grease and dirt
.
Dis
p
osa
l
The device must be disposed of properly and in accordance with statutory regulations (Electrical and
Electronic Equipment Act)
.
EDDYTHERM operating manual
10
Type
Ser.Nr.
Herst.Dat.
V˜/A
COSφ
kW/kVA
Hz /Phasen
CISPR 11/IEC 55011 Klasse B
Zeichn.Nr.
Gew., kg
PRÜFTECHNIK
Alignment Systems GmbH
D-85737 Ismaning
www.pruftechnik.com
Operating notes
To ensure that the equipment operates smoothly, note the following instructions.
Temperature range
Operation
The allowable operating temperature is between 0°C and 40°C. Higher temperatures may lead to the destruction of
the components. The device can be used at relative humidity levels of up to 90% and at altitudes up to 3000 m.
Storage and transport
Store and transport the EDDYTHERM device at temperatures between -20° C and 60° C.
Storage and transport can take place at a relative humidity of up to 90% and at any altitude. Always use the original
packaging when transporting the equipment.
Type label
The type label is located on the lower left side of the EDDYTHERM 4X unit (see illustration on page 12) or on the
underside of the EDDYTHERM Ix and I-6 units.
EDDYTHERM operating manual
11
EDDYTHERM 1x / EDDYTHERM 1-6
Features at a glance
User-oriented operating modes and displays
› Temperature selection
› Time selection
› Automatic demagnetization after every heating cycle
› Reduced-power heating option in 20% steps (100%, 80%, 60%, 40%, 20%)
› Digital display of preset and measured values
› Digital display of temperature and remaining heating time
› Acoustic announcement of cycle completion
Simple operation
› Simple control panel
Robust, industrial design
› Heavy-duty construction
› Control panel resistant to dust, oil and dripping water
Microcontroller-driven electronics
› Service-friendly plug-in unit
› Electronics with self-diagnostic troubleshooting codes
Powerful
› Up to 98% efficiency
› Power factor cosϕis highest in the industry
Compact and portable
Crossbar
Control panel
Mounting column
Connector for temperature
probe
EDDYTHERM operating manual
12
EDDYTHERM 4x
Features at a glance
User-oriented operating modes and displays
› Temperature selection
› Time selection
› Automatic demagnetization after every heating cycle
› Reduced-power heating option in 20% steps (100%, 80%, 60%, 40%, 20%)
› Digital display of preset and measured values
› Digital display of temperature and remaining heating time
› Acoustic indication of cycle completion
Simple operation
› Simple control panel
› Convenient swivel crossbar
Robust, industrial design
› Heavy-duty steel construction
› Control panel resistant to dust, oil and dripping water
› Resin coating protects against impact and corrosion damage
Microcontroller-driven electronics
› Service-friendly plug-in unit
› Self diagnostic troubleshooting codes
› Installed in sheet steel housing
Powerful
› Available to suit any supply voltage from 200-600 V, 50/60 Hz
› Up to 98% efficiency
› Power factor cosϕis highest in the industry
Mobile
› Heavy duty wheels and casters
› Foot operated parking brake
Control panel
Connector for temperature probe
Swivel crossbar
Electronics
Type label
Swivel crossbar
pedal
Retractable
workpiece rail
EDDYTHERM operating manual
13
EDDYTHERM control panel
Brief description of operating modes and functions
Temperature hold
The workpiece is heated to the set temperature and held at that temperature until it is needed. It is automatically
demagnetized before it is removed.
Temperature shutoff
The workpiece is heated to the set temperature and then demagnetized. An acoustic signal indicates completion of
the heating process.
Timed shutoff
The workpiece is heated for the set duration and then demagnetized. An acoustic signal indicates completion of the
heating process. This program must be selected when heating without the temperature probe or heating large or
heavy workpieces that heat very slowly.
Reduced-power heating option
This function makes it possible to run the powerful heater at full power or at reduced power in 20% steps. This
ensures that small workpieces are not overheated or heated too quickly (an important consideration for C1/C2
bearings).
Demagnetization
Workpieces may be demagnetized at any time without being heated first.
Program interruption
If the heating cycle in progress is aborted by pressing the STOP key, the demagnetization process takes place
automatically.
The selected operating mode or function is indicated by the corresponding indicator LED.
STOP
Reduced-power
heating option
Operating modes Indicator LED Temperature/time adjustment key
Digital display
Indicator LED
Manual
demagnetization
EDDYTHERM operating manual
14
Starting EDDYTHERM
EDDYTHERM 4x cable holder
EDDYTHERM 4x is provided with a bracket upon which excess power cable may be hung to avoid damage or the
danger of tripping.
Setup
Simply plug the heater into the power socket. The indicator LED for the “temperature shutoff” operating mode
lights up.
Switching off
If the induction coil becomes overheated due to extended operation under heavy workloads, EDDYTHERM auto-
matically switches itself off until the coil has cooled off sufficiently. EDDYTHERM then switches itself back on.
Never disconnect the device from the power supply while it is heating a workpiece.
N
ever disconnect the device from the power suppl
y
while it is heatin
g
a workpiece
.
EDDYTHERM operating manual
15
Mounting the workpiece
To achieve the best possible efficiency, always choose the largest possible crossbar. This is the only way to guarantee
that the workpiece will be heated rapidly.
Slide the workpiece onto the crossbar and then place the crossbar onto the columns with the unpainted side facing
down. The laminates of the bar are now in a vertical position.
Mount the workpiece horizontally
Workpieces with a large inside diameter heat up more quickly when they are mounted horizontally.
Small workpieces
To heat very small workpieces, they can be placed in pairs (as shown in Fig. 4) between the crossbar and columns.
For reasons of symmetry, the two workpieces should always have the same thickness.
To prevent the rapid conduction of heat away from the heated workpiece to the cold contact surfaces of the
bar and column, a heat insulating material can be placed above and below the workpiece (often a sheet of
paper will be sufficient).
To prevent the rapid conduction o
f
heat away
f
rom the heated workpiece to the cold contact sur
f
aces o
f
the
b
ar and column, a heat insulatin
g
material can be placed above and below the workpiece (often a sheet of
p
a
p
er will be sufficient).
Poor Good
1
2
3
4
1 2
34
Note
EDDYTHERM operating manual
16
Multiple identical workpieces
Multiple workpieces can be heated together if they are identical, i.e., have the same weight and the same
dimensions.
Demagnetization of tools
Mount the demagnetization bar (optional) as shown in the figure below.
Press the demagnetization key and hold the tool in the gap of the demagnetization bar.
5
6
5 6
EDDYTHERM operating manual
17
EDDYTHERM 4
EDDYTHERM 4
R
EDDYTHERM 4x swivel crossbar
The swivel crossbar greatly reduces the effort required to mount large, heavy bearings. The swivel crossbar is first
raised using the foot pedal and then turned easily to one side.
In this way, heavy bearings can be mounted on the swivel crossbar using suitable lifting gear.
When it is swiveled back, the crossbar locks back into place. Do not lower the bearing until the swivel crossbar is
closed (danger of tipping).
Never start the heating process while the swivel crossbar is open (danger of injury).
Mounting the bearings
Small to medium-size workpieces can be heated either when hanging from or resting on the EDDYTHERM. When
heating large bearings, it is recommended that the bearing be mounted in a horizontal position, for reasons of
better efficiency.
Bearing size
The powerful EDDYTHERM 4x can heat workpieces or roller bearings weighing in excess of 200 kg in a short period
of time (example: bearing 23088, 180 kg/396 lb, heated from 20°C/68°F to 100°C/212°C in approx. 8 minutes).
The standard swivel crossbar accepts workpieces with inside diameters from 108 mm on up. Additional swivel and
mounting crossbars are available optionally for smaller workpieces; see page 29.
Never start the heating process while the swivel crossbar is open (danger of injury)
.
1
2
3
4
EDDYTHERM 4
EDDYTHERM 4
R
VIBROTIP
PRUFTECHNIKAG
R
M
ON
1 2
3
4
Maximumload on
swivel crossbar when
loading and unloading:
60 kg
Maximumload
when mounted
horizontally: 300 kg Maximumload
when mounted in a
hanging position:
200 kg/440 lb (only with
swivel crossbar closed)
EDDYTHERM operating manual
18
Bearings with brass or bronze cages
When bearings with brass or bronze cages are to be heated, care must be taken to ensure that the cage does not
heat faster than the inner bearing ring. This could cause the lubrication contained in the bearing pockets to become
overheated, which in turn could, in extreme cases, lead to overheating of the rolling elements themselves. In this
case, use a hand-held thermometer to monitor the cage temperature separately and interrupt the heating cycle or
use the reduced-power heating option to avoid overheating of the cage.
C1 and C2 bearings
When heating bearings with limited clearance (such as C1 and C2 series bearings), it is possible that the inner
ring may heat more rapidly and expand much faster than the outer race, causing the bearing to “freeze up”
during heating. Therefore, rotate these bearings during heating to make sure that they turn freely and, if necessary,
interrupt the heating cycle or use the reduced-power heating option to allow the outer ring to heat up
EDDYTHERM operating manual
19
Temperature probe
The EDDYTHERM can be operated with automatic temperature detection using two different types of temperature
probes.
Magnetic probe
This temperature probe [ETH 7305] is equipped with a powerful permanent magnet that attaches itself to any
ferromagnetic material. It may be used at temperatures up to 240°C/464°F.
Attaching the magnetic probe
Attach the probe to the side of the workpiece: in roller bearings, it should be applied at the top of the inner ring
(heat rises).
Detaching the magnetic probe
Remove the probe only by pulling on the holder and not on the cable. Wear protective gloves.
The workpiece may be hot.
1
2
3
1
2 3
EDDYTHERM operating manual
20
Clip-type probe [ETH 7305] (optional)
This temperature probe with a clip-on holder is suitable for temperatures up to 140°C/284°F. It is attached so that
the measurement point is located on the side or inside of the workpiece. Unlike the magnetic probe, the clip-type
probe can be attached to non-magnetic workpieces (aluminum, stainless steel).
If the side surfaces of the inner ring of the bearing are too narrow for the magnetic probe, the clip-type probe should
be used.
Connecting the temperature probe
The connector of the temperature probe is plugged into the connector next to the keypad (or to the right beneath
the control panel in the 4x), and is locked with the threaded bushing.
The EDDYTHERM recognizes the connected probe type and automatically limits the temperature programming to
the highest allowable value in each case.
5
6
4
45
6
EDDYTHERM I-6
Made in Germany
R
R
MIN
°C
°F
START
STOP
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