Schaeffler HEATER Series User manual

Induction Heaters
BASIC Series - Bench-top devices
User manual

2Schaeer Technologies
Read the manual and safety instructions before
operating the device
Check all parts for possible damage during transportation.
In case of damage, please contact the carrier immediately.
Because our products are continuously subject to
improvements, we reserve the right to make changes.
Vor Inbetriebnahme die Betriebsanleitung und die
Sicherheitsvorschriften aufmerksam lesen
Alle Teile auf möglichen Transportschaden kontrollieren.
Eventuelle Schäden umgehend der Spedition melden. Da
unsere Produkte ständig verbessert werden, behalten wir uns
Änderungen vor.
Antes de la primera puesta en marcha, lea atentamente el
manual de uso y las instrucciones de seguridad
Revise todos los elementos para detectar posibles daños
sufridos durante el transporte. En caso de observar algún
daño, avise inmediatamente a la empresa de transporte.
Debido a que nuestros productos están continuamente sujetos
a mejoras, nos reservamos el derecho de realizar cambios.
Lisez le mode d’emploi et les consignes de sécurité avant la
mise en service
Vérifiez pour l’ensemble des pièces que celles-ci n’ont pas été
endommagées pendant le transport. En cas de dommages,
avertissez immédiatement le transporteur. Nos produits
étant constamment améliorés, nous nous réservons le droit
d’apporter des modifications.
Lees voor ingebruikname eerst de gebruiksaanwijzing
en de veiligheidsvoorschriften
Controleer alle onderdelen op mogelijke transportschade.
Waarschuw bij schade onmiddellijk het transportbedrijf. Omdat
onze producten voortdurend worden verbeterd, behouden wij
ons het recht voor om wijzigingen aan te brengen.
Address Schaeer Technologies AG & Co. KG
Georg-Schäfer-Straße 30
97421 Schweinfurt, Germany
Tel [phone]
Web www.schaeer.com/services
Mail support.is@schaeer.com
ISO ISO 9001: 2015
Contact
Warning!

Schaeer Technologies 3
The induction heating devices HEATER20-BASIC, HEATER50-
BASIC, HEATER100-BASIC, HEATER150-BASIC and HEATER200-
BASIC give rapid, clean operation. Their high eciency level
allows energy-ecient heating and shorter mounting times.
This reduces the operating costs. The uniform, controlled
heating allows consistently good quality of mounting.
Operation is simple and user-friendly, the touch-sensitive
screen is oil-resistant, dustproof and waterproof.
When heating by induction is used, there is no need at
all to use oil – this gives particularly good environmental
compatibility. The scope of application is very extensive.
It is possible to heat the loose inner rings of cylindrical or
needle roller bearings as well as sealed and greased bearings.
Compared with previous models, further improvements have
been made in performance capacity and safety and the part to
be heated need no longer be of a minimum mass.
In order to ensure durability in demanding industrial
operation, the devices are extremely robust and reliable.
Foreword

4Schaeer Technologies
Contents
1. About the user manual..................................................................................................................5
1.1 Current version .......................................................................................................................... 5
1.2 Availability................................................................................................................................. 5
1.3 Legal guidelines ........................................................................................................................ 5
1.4 Original user manual ................................................................................................................. 5
2. Safety, warnings and potential hazards ........................................................................................ 6
2.1 Explanation of the pictograms................................................................................................... 6
2.2 Description of potential hazards ............................................................................................... 7
2.3 Safety measures to be taken .................................................................................................... 9
2.4 Safety provisions .................................................................................................................... 10
3. Introduction ................................................................................................................................11
3.1 Application .............................................................................................................................. 11
3.2 Operating conditions .............................................................................................................. 11
3.3 Principle of operation .............................................................................................................. 11
4. Installation..................................................................................................................................12
5. Explanation of display and keys..................................................................................................14
6. The magnetic temperature sensor .............................................................................................15
7. Method of operation ...................................................................................................................16
7.1 Heating a hanging workpiece .................................................................................................. 17
7.2 Heating a horizontal workpiece .............................................................................................. 18
7.3 Maximum weights for swivel arm models................................................................................ 19
8. Operation ....................................................................................................................................20
8.1 Selecting heating modes ......................................................................................................... 21
8.2 Heating in time mode .............................................................................................................. 21
8.3 Workpiece installation ............................................................................................................. 21
8.4 Error message ......................................................................................................................... 22
8.5 Switching between Celsius and Fahrenheit ............................................................................. 22
9. Cleaning, maintenance and troubleshooting ..............................................................................23
10. Technical specifications ............................................................................................................25
11. Waste disposal..........................................................................................................................27
12. Disclaimer .................................................................................................................................27
13. Certificate of conformity............................................................................................................28
English

Schaeer Technologies 5
The original user manual is taken to be a user manual in the
English language. A user manual in another language is to be
taken as a translation of the original user manual.
1. About the user manual
1.1 Current version
1.2 Availability
1.3 Legal guidelines
This user manual is supplied with each device and can also be
ordered retrospectively.
A current version and translations of this user manual, can be
found at “www.schaeer.de/publications-heater” using the
search term ‘HEATER-BASIC’.
The information in this manual corresponded to the most
recent status at the close of editing. The illustrations and
descriptions cannot be used as grounds for any claims relating
to devices that have already been delivered. Schaeer
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.
1.4 Original user manual

6Schaeer Technologies
Forbidden for persons with heart pacemaker
or other sensitive implants.
Wearing of metal parts, watches and
jewellery forbidden.
Forbidden for persons with metal implants.
Forbidden for magnetically sensitive
data media.
Read the user manual!
Wear heat-resistant gloves!
Wear safety shoes!
Warning of danger.
Electric shock hazard.
Warning of magnetic fields.
Warning of hot surface.
Warning of heavy object.
2. Safety, warnings and potential hazards
2.1 Explanation of the
pictograms

Schaeer Technologies 7
Warning! Voltage
Be aware that you are working with an
electrical appliance. On the mains side as
well as internally, voltages occur that can lead
to serious injury and death if used inexpertly
or improperly.
■Connect the unit to the power according to
the information on the rating plate.
■Before each use, check the power supply
cable for damage.
■Safe disconnection from the power supply
must be ensured at all times before
starting maintenance and repair work. This
can be achieved by removing the power
plug from the socket.
Warning! Electromagnetic field
Be aware that you are working with an
appliance that generates electromagnetic
fields. Keep a distance of 1 metre from the
unit when switching on.
These fields can be harmful for persons with
active medical aids such as heart pacemakers.
These fields can be harmful for persons
with passive medical aids such as joint
prostheses. The wearing of jewellery can also
result in injuries due to burns.
It is forbidden for persons with active medical
aids to be in the immediate vicinity of the
unit when it is in operation. The generated
electromagnetic field may influence the
proper function of such medical aids.
It is forbidden to wear jewellery when working
with the generator and inductors. There is
a risk of the jewellery being heated by the
electromagnetic field and resulting in injuries
due to burns.
For this reason, persons with passive
implants are recommended not to enter the
immediate vicinity of the induction heater
when it is in operation.
2.2 Description of
potential hazards

8Schaeer Technologies
Furthermore, it cannot be ruled out that the
electromagnetic fields could cause damage to
electronic and magnetic data media. Keep such
equipment away from the induction heater.
Caution! Tripping hazard
Limit the risk of injury due to tripping as
far as possible.
■Keep your place of work tidy. Remove any
loose and superfluous objects from the
immediate vicinity of the unit.
■Position any (power supply) cables as
low as possible to minimise the risk
of tripping.
Caution! Risk of burns
The workpiece becomes warm to very hot
during heating.
Parts of the unit may also become hot due
to contact with the workpiece or the heat
radiated by the workpiece.
Therefore always wear heat-resistant gloves
when handling workpieces in order to avoid
injury due to burns.
Caution! Risk of injury during lifting
A number of units in the Schaeer heater
range weigh more than 23 kg and may
therefore not be lifted by one person alone.
(see technical specs)
If a unit weighs more than 23 kg, lift it with
two persons or use suitable
lifting equipment.
Wear safety shoes to prevent injury from
unintentionally falling workpieces and/or
machine parts.

Schaeer Technologies 9
■The user must carefully read this manual and be familiar with
the safety standards in the work practice.
■Follow the instructions in the manual at all times.
■Check the connection voltage against the rating plate on
the unit. If the power cord does not have one, make sure
it is fitted with the proper plug. This must be fitted by a
qualified electrician.
■Never use or store an induction heater in a
damp environment.
■Only use Schaeer induction heaters indoors.
■If using a mobile version; always lock the castors when not
moving the device.
■If the heater is equipped with extendable horizontal supports,
always secure them with the appropriate locking pin, both in
the fully retracted and in the fully extended position.
■Use suitable lifting equipment according to the weight of
the ledge or component.
■Never use a metal strap to support workpieces or suspend
them in the magnetic field. High currents could start
running through the strap, causing it to heat up.
■Do not hold metal objects near ledge and poles.
■Whilst heating, observe a minimum distance of 1 metre
from the heater.
■Never remove the induction ledge during heating.
■Do not modify the heater. Never use home-made ledges.
■Always check that the induction ledge is positioned
correctly against the poles, so excessive vibration cannot
cause personal injury or damage to the device.
■Do not switch on the heater until the core is closed with
a ledge.
Hazard area
The hazard area of the heating device can represent a danger
of death.
DANGER!
Danger of heart stoppage in persons fitted with
a pacemaker due to the strong electromagnetic
field. Ensure that persons fitted with a
pacemaker remain outside the hazard area of
the heating device. Erect barriers and attach
clearly visible warning signs, Figure 1.
2.3 Safety measures
to be taken

10 Schaeer Technologies
■The electronic systems switch o automatically if the
ambient temperature rises above 70ºC.
■When heating in temperature mode, the heater switches o
if no 1°C temperature increase is measured during a time
pre-set by the manufacturer.
■The coil of the heater is equipped with a temperature
monitor. If the coil becomes too hot, the heating process is
switched o entirely.
■Models with a swivel arm are equipped with a safety
positioning cam.
An induction heater operates by means of a magnetic field.
At a distance of 1 metre, the magnetic field has been reduced to
such an extent that it is below the applicable standard of 0.5mT.
2.4 Safety provisions
WARNING!
Danger of death for persons with artificial
heart valves made from metal, hazard of
severe burns due to heating of implants by the
electromagnetic field, see chatper 2.2.
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 1.
1 m
2
1
3
1. Hazard area, 1m
2. Barrier
3. Flat work surface capable
of supporting load
Figure 1

Schaeer Technologies 11
The operation of the heater is based
on inducing a (low frequency) current
in the bearing. This is achieved
by incorporating the bearing as a
secondary winding in a transformer.
The primary winding is connected to
the mains by means of an electronic
controller. The magnetic field induces
a high current (short-circuit current)
through the bearing, which then becomes hot. After each
heating cycle, the bearing or workpiece is demagnetized.
3.2 Operating conditions ■Only use the device indoors.
■Fit for use in an industrial environment, at an ambient
temperature of 0ºC (32°F) to 50ºC (120°F) and humidity of
5 to 90% – non-condensing.
At temperatures below 0°C (32°F), the unit stops operating.
3.3 Principle of operation
Schaeer induction heaters are intended for heating
bearings, so they can be assembled easily by means of a
shrink fit. Subject to professional assessment, they can also
be used to heat bushings, cogwheels, couplings and metal
objects that form a closed circuit. Bearings and workpieces are
demagnetized automatically after each heating cycle.
Bearings and workpieces can be heated to a maximum
temperature of 240ºC (464°F), except for the HEATER20-BASIC
type where the maximum temperature is set at 150ºC (300°F).
Schaeer induction heaters are suitable for continuous use.
However, when heating to 240°C (464°F), don’t do so for more
than half an hour. HEATER20-BASIC has a duty cycle of 1,5 hour.
CAREFUL!
■Bearings may be heated to a maximum of 120°C (248°F).
■Precision bearings may be heated to a maximum
of 70°C (158°F). Higher temperatures can aect
metallurgical structure and lubrication, resulting in
instability and failure.
■Do not use a heater for bearings and workpieces that
are outside the minimum and maximum dimensions
specified in the technical specifications.
■Never switch o the unit with the main switch while it
is still heating up.
3.1 Application
3. Introduction

12 Schaeer Technologies
■Remove the packaging and place the induction heater on
a non-ferrous, stable and level surface. Put heaters with
wheels on the brake to prevent the heaters from moving.
■A Schaeer heater is supplied with ledges, temperature
sensor, heat-resistant gloves (suitable up to 250°C / 482°F)
and acid-free lubricant.
■Check the connection voltage against the rating plate on
the unit.
■Each heater is equipped with a plug. As there is a wide
variety of plug types, the attached plug may not fit. In
such cases, obtain a proper plug. It must be fitted by a
qualified electrician. There are 2 fitting options depending
on the type of cable on the heater:
120V/230V 1 phase heaters
Brown Phase
Blue Zero
Green/Yellow Ground
120V/240V 1 phase heaters
Black Phase
White Zero
Green Ground
400V/450V/500V 2 phase heaters
Brown Phase
Blue or
Black Zero
Green/Yellow Ground
480V/600V 2 phase heaters
Black Phase
White or
Black Zero
Green Ground
4. Installation

Schaeer Technologies 13
■Ensure that the power supply cable cannot come into
contact with the workpiece to be heated. Insert the plug in
a grounded socket outlet with connection.
■Switch on the device by means of the main switch. The
machine briefly shows “Test”, and the display shows a “pre-
set end temperature” programmed by the manufacturer.
■Connect the temperature sensor by inserting the plug
into the socket. Make sure that the – and + of the plug
correspond to that of the socket.
■The induction heater is now ready for use in the
temperature mode.

14 Schaeer Technologies
5. Explanation of display and keys
1. Time or temperature up
2. Heating in time mode
3. Start heating after setting
time/temperature
4. Display: time or
temperature
5. Time or
temperature down
6. Heating in
temperature mode
7. Stop heating /
automatic demagnetise
1
2
3
4
5
6
7

Schaeer Technologies 15
■The magnetic temperature sensor must always be used
when heating in “temperature mode”.
■The sensor can be used as a tool for temperature control
whilst heating in “time mode”.
■The sensor is suitable for a maximum temperature of 240ºC
(464°F).
■In the event of temperatures exceeding 240ºC (464°F),
the connection between the magnet and the sensor is
interrupted. The heater switches o automatically when the
sensor does not detect a temperature increase.
■Special clamp sensors are available for non-magnetic
workpieces.
■Make sure that the sensor and workpiece surfaces are clean.
■Always place the sensor on a flat area as close as possible
to the bore. Connect the sensor by inserting the plug into
the socket (in the casing). Make sure that the – and + of the
plug correspond to that of the socket.
6. The magnetic temperature sensor
Careful!
Handle the sensor with care! It is a vulnerable part of the
heater. After use, place the sensor on the side of a
vertical pole.

16 Schaeer Technologies
7. Method of operation
WARNING!
Use suitable lifting equipment for heavy
ledges and workpieces. Prevent personal
injury by improper handling.
The weight of the workpiece may not exceed the
value given in section 7.3 and in the technical
specifications. This can cause failure of the
device and personal injury.
Ensure that the power supply cable cannot
come into contact with the workpiece to
be heated. Damage to the cable can cause
electrocution!
Never use a metal strap to support workpieces
or suspend them in the magnetic field. High
currents could start running through the strap,
causing it to heat up.
A workpiece can be placed in 2 dierent ways:
Hanging, with ledge through the workpiece

Schaeer Technologies 17
Large workpieces can be thermally insulated by wrapping them
in insulating material, such as a welding blanket. This ensures
that the heat stays in the workpiece and does not dissipate.
Horizontal, with workpiece around the pole
■Place the induction ledge with the bearing on the poles.
Make sure that the ground side is positioned straight on
the poles.
■Always choose an induction ledge that fills the bore of the
bearing as much as possible. You can even use 2 ledges at the
same time. This promotes optimal, fast and even heating.
■Make sure that the bare-metal sides are suciently coated
with lubricant to ensure optimal contact and avoid vibration.
7.1 Heating a hanging
workpiece

18 Schaeer Technologies
■Swivel arm models: swivel the ledge open (towards you)
until it clicks in the safety positioning cam. Slide the
workpiece over the ledge until it is in the middle.
Swivel the ledge back to the pole.
■Always make sure that the workpiece does not come into
contact with the plastic casing of the heater. When the
heating is finished, follow the instructions in reverse order.
Use heat-resistant gloves to move the heated workpiece.
■This is only possible if the bore of the workpiece is large
enough to fit over the pole.
■Place the workpiece as centrally as possible around the
pole on the horizontal supports.
■The workpiece may not be wider than the
horizontal supports.
■Always choose the largest induction ledge.
■Make sure that the bare-metal sides are suciently coated
with lubricant to ensure optimal contact and avoid vibration.
7.2 Heating a horizontal
workpiece
■Always make sure that the workpiece does not come into
contact with the plastic casing of the heater. When the
heating is finished, follow the instructions in reverse order.
Use heat-resistant gloves to move the heated workpiece.

Schaeer Technologies 19
7.3 Maximum weights for
swivel arm models
Table for maximum permitted weights on the horizontal
support and the (swivel) ledges:
Size of (swivel) ledge
Type On
supports
7
mm
10
mm
14
mm
20
mm
30
mm
40
mm
50
mm
60
mm
70
mm
HEATER20-BASIC n/a 1 kg 2 kg 3 kg 5 kg n/a 20 kg n/a n/a n/a
HEATER50-BASIC 50 kg 1 kg 2 kg 3 kg 5 kg 10 kg 15 kg n/a n/a n/a
HEATER100-BASIC 100 kg n/a 2 kg 3 kg 5 kg 10 kg 15 kg 20 kg n/a n/a
HEATER150-BASIC 150 kg n/a n/a n/a 10 kg 15 kg 25 kg 40 kg 45 kg 50 kg
HEATER200-BASIC 200 kg n/a n/a n/a 10 kg 15 kg 25 kg 40 kg 45 kg 50 kg
■Keep to these maximum weights and avoid tilting the
heater or damaging the supports, (swivel) ledges or hinge.
■Workpieces with a higher weight can rest on the supports
or be supported by a non-metallic sling of a crane, to
prevent any weight resting on the ledge.
CAREFUL!
■Always handle induction ledges with care. They are
damaged easily when dropped, knocked against
something, etc. Store them immediately after use.

20 Schaeer Technologies
There are 2 heating methods:
Temperature mode
■For controlled heating up to the desired temperature.
■And if you want to make use of the thermostat feature.
This feature maintains the heated workpiece at the pre-
set temperature for a maximum period of 5 minutes.
Time mode
■Suitable for series production. If the time needed to
reach a certain temperature is known, the workpiece
can be heated in series with the time mode.
■In the event of an emergency. If the sensor is faulty, as
a contingency measure, the workpiece can be heated
with the time mode. The temperature can be measured
with an external thermometer.
■In incidental cases when workpieces are too big for
the heater, which in temperature mode would lead
to an error message due to an insucient increase
in temperature, the time mode may be a solution. If
this is often the case, choose a bigger heater from the
Schaeer range.
8. Operation