Schaeffler SMART Series User manual

Induction Heaters
SMART Series
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 forwarder 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
Machine ID and
certification See machine plate
Contact
Warning!

Schaeer Technologies 3
The induction heating devices HEATER50-SMART, HEATER100-
SMART, HEATER150-SMART, HEATER200-SMART, HEATER400-
SMART, HEATER600-SMART, HEATER800-SMART and
HEATER1600-SMART 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

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Contents
1. About the user manual..................................................................................................................6
1.1 Current version .......................................................................................................................... 6
1.2 Availability................................................................................................................................. 6
1.3 Legal guidelines ........................................................................................................................ 6
1.4 Original user manual ................................................................................................................. 6
2. Safety, warnings and potential hazards ........................................................................................ 7
2.1 Explanation of the pictograms................................................................................................... 7
2.2 Description of potential hazards ............................................................................................... 8
2.3 Safety measures to be taken .................................................................................................. 10
2.4 Safety provisions .................................................................................................................... 11
3. Introduction ................................................................................................................................12
3.1 Application .............................................................................................................................. 12
3.2 Operating conditions .............................................................................................................. 12
3.3 Principle of operation .............................................................................................................. 12
4. Installation..................................................................................................................................13
5. Explanation of display, buttons and connections ......................................................................15
5.1 Explanation of touchscreen operating elements ..................................................................... 16
6. System settings ..........................................................................................................................18
6.1 General.................................................................................................................................... 18
6.2 Explanation of system settings – screen 1 .............................................................................. 19
6.3 Explanation of system settings – screen 2 .............................................................................. 19
6.4 Explanation of system settings – screen 3 .............................................................................. 20
6.5 Explanation of system settings – screen 4 .............................................................................. 21
6.6 Explanation of system settings – screens 5 and 6 ................................................................... 21
7. The magnetic temperature sensor .............................................................................................23
8. Method of operation ...................................................................................................................24
8.1 Heating a hanging workpiece .................................................................................................. 26
8.2 Heating a horizontal workpiece .............................................................................................. 27
8.3 Maximum weights for swivel arm models................................................................................ 27
9. Operation ....................................................................................................................................28
9.1 Selecting heating modes......................................................................................................... 29
9.2 Heating in temperature mode ................................................................................................. 32
9.3 Heating in time mode .............................................................................................................. 34
9.4 Heating in temperature or time mode...................................................................................... 35
9.5 Heating in temperature & speed mode ................................................................................... 37
9.6 Workpiece installation............................................................................................................. 39
9.7 Error messages........................................................................................................................ 39
English

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10. Log functionality .......................................................................................................................41
10.1 Logging ................................................................................................................................. 41
10.2 Access to the log files ............................................................................................................ 44
10.3 Alarms ................................................................................................................................... 44
10.4 Last crash .............................................................................................................................. 45
10.5 Heating logs .......................................................................................................................... 46
11. Other functionalities .................................................................................................................48
11.1 Demagnetisation................................................................................................................... 48
11.2 Hold functionality .................................................................................................................. 48
11.3 ΔT functionality ..................................................................................................................... 51
11.4 Target functionality ................................................................................................................ 53
12. Cleaning, maintenance and troubleshooting ............................................................................54
13. Technical specifications ............................................................................................................56
13.1 Technical specifications HEATER50-200 ................................................................................ 56
13.2 Technical specifications HEATER400-1600 ........................................................................... 57
13.3 Machine ID and certification ................................................................................................. 58
13.4 Ledges (Yokes) ...................................................................................................................... 60
13.5 Scope of delivery ................................................................................................................... 61
14. Waste disposal..........................................................................................................................62
15. Disclaimer .................................................................................................................................62
16. Certificate of conformity............................................................................................................63

6Schaeer Technologies
The original user manual is taken to be a user manual in the
Dutch 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.
An induction heating unit is controlled by means of an operator
unit with a touch-sensitive screen. The operator software can
be developed further and an update is possible free of charge.
Changes to the software can lead to adjustments in the user
manual. A current version and translations of this user manual,
can be found at “www.schaeer.de/publications-heater” using
the search term ‘HEATER-SMART’.
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

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Forbidden for persons with a 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

8Schaeer Technologies
Warning! Voltage
Be aware that you are working with an
electrical device. 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 device
that generates electromagnetic fields. Keep
a distance of 1 metre from the unit after
switching on.
These fields can be harmful for persons with
active medical aids such as 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

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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 suply) cables, as low
as possible to minimize 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.

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■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

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■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 chapter 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

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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.
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).
Schaeer induction heaters are suitable for continuous use.
However, when heating to a temperature of 240°C (464°F), do
not so for more than half an 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
3.2 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
3. Introduction

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■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, 2 temperature
sensors, heat-resistant gloves (suitable up to 250°C /
482°F) and acid-free grease.
■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 dierent fitting options depending on the type of
cable on the heater:
Fitting options HEATER50 - 200 SMART
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
4. Installation

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480V/600V 2 phase heaters
Black Phase
White or
Black Zero
Green Ground
Fitting options HEATER400 - 1600 SMART
400V/450V/500V 2 phase heaters
Brown Phase
Black Phase
Green/Yellow Ground
480V/600V 2 phase heaters
Black Phase
Black Phase
Green Ground
■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.
■Ensure that the power supply cable cannot come into
contact with the workpiece to be heated. Insert the plug in
a socket outlet with grounded connection.
■Switch on the device by means of the main switch. The
machine is starting up.
■While the machine is starting up, a logo is displayed on the
screen. Starting up takes some time.

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Sensor connections T1 and T2:
T1 (red on display) is the main
temperature that controls the
heating process.
T2 (green on display) is an
additional measurement
that can be used to monitor
and adjust a temperature
dierence, ΔT, in a workpiece
during heating.
USB port for logging purposes
(stored heating data).
5. Explanation of display, buttons
and connections
Touchscreen:
time or temperature
heating mode
settings
information
red temperature = T1
green temperature = T2
Start /Stop button:
heating / automatic
demagnetisation

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Dierent pages are displayed on the screen with i.a. dierent
buttons, setting possibilities and operating modes.
The most frequently used buttons and how variables can be
set are explained below.
Start heating process.
Stop heating process.
To settings menu.
To administrator (factory) settings.
Not accessible to the end user.
Back / previous screen.
To next page.
To previous page.
5.1 Explanation of
touchscreen operating
elements
The operating panel consists of a touchscreen.

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Reset appliance to default settings.
Call up additional heating information.
Adapt target heating during heating process.
Access to log data.
Sliders on/o. The corresponding option is
switched on or o.
Slider “not available”. The corresponding option
cannot be switched on or o due to settings
made elsewhere.
Variables can be set or changed by tapping them.
Usually, a selection menu or keypad is then displayed. This
principle applies to every screen. With the help of the sliders,
elements can be switched on or o.

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With the buttons “page forward” , “page back” and
“back / previous page” the user can navigate through the
various settings pages.
Tapping allows its settings to be changed.
An “ADMIN” button is displayed on this screen.
Settings are made by the manufacturer in the Admin settings.
These settings are essential for the type of heater and are
not at the user level and are therefore not accessible. These
settings are protected by a password.
The heater oers the possibility to set and adjust parameters
according to personal wishes and preferences. The parameters
can be set according to the demands made on a heating
process. Pressing settings displays the following screen:
6. System settings
6.1 General
About Admin settings

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6.3 Explanation of system
settings – screen 2
Default Temperature hold:
Default temperature hold on or o
6.2 Explanation of system
settings – screen 1
Default mode:
Heating mode to which the heater is set and in which it starts
for the first time, or to which it returns if “Default” is pressed.
Default temp:
Setpoint temperature at which the heater starts, or to which it
returns if “Default” is pressed.
Default time:
Setpoint time with which the heater starts, or to which it
returns if “Default” is pressed.
Default max. speed:
Maximum setpoint, maximum heating speed in the
temp&speed modes. This does not mean that the heater will
always reach this speed. This depends, among other things,
on the geometry of the workpiece, the ledge used, etc.

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Oset Temperature probe 1:
Calibration / correction readout thermocouple 1
Oset Temperature probe 2:
Calibration / correction readout thermocouple 2
Unit:
Setting of the temperature measurement in °C or °F.
Language:
Setting of the language in which the texts on the screen are
displayed. Choice of Dutch, English, German and Italian.
6.4 Explanation of system
settings – screen 3