simatherm IH 210 User manual

Bedienungsanleitung
Instructions for use
Mode d‘emploi
Manuale d‘istruzioni
Manual de instrucciones
Induction Heater IH 210

2 Induktionsheizgerät IH 210 © simatec ag

© simatec ag Induction Heater IH 210 17
English
Table of contents
EU Declaration of conformity 18
Safety recommendations 19
1 Introduction 20
1.1 Intended use 20
1.2 Principle of operation 20
1.3 Distinguishing feature 21
2 Technical description 21
2.1 Components 21
2.2 Technical data 22
3 Installation of mains plug 22
4 Preparation for use 23
5 Operation 24
5.1 Function of displays 24
5.2 Function of buttons 24
5.3 Temp Mode 25
5.4 Time Mode 26
5.5 Temperature measurement 26
5.6 Change of temperature unit 26
5.7 Demagnetisation 26
5.8 Power level selection 27
6 Safety features 27
7 Troubleshooting 28
8 Spare parts 29

18 Induction Heater IH 210 © simatec ag
EU Declaration of conformity
simatec ag
Stadthof 2, CH-3380 Wangen a. Aare, Switzerland
declares that the
Induction Heaters
simatherm IH 210
are designed and manufactured in accordance with
Directive 2006/95/EC of the European Parliament and of the Council
relating to electrical equipment designed for use within certain
voltage limits
Directive 2004/108/EC of the European Parliament and of the Council
relating to electromagnetic compatibility and repealing
Directive 89/336/EEC
The following standards have been applied:
EN 60519-1
EN 60519-3
EN 55011
EN 61000-3-3
EN 61000-6-2
Wangen a. Aare, 2012-06-06
Mischa N. Wyssmann
Managing Director / CEO

© simatec ag Induction Heater IH 210 19
English
Safety recommendations
• Because the IH 210 generates a magnetic field, people wearing a
pacemaker must not be within five meters of the IH 210 during ope-
ration. Electronic equipment, such as wristwatches, may also be affec-
ted.
• Follow the operating instructions at all times.
• Be certain that the voltage supply is correct.
• Electrical arcing may occur when a potential difference exists between
the IH 210 and the workpiece. This is not dangerous to human
beings and will not cause damage to the IH 210 or the workpiece.
However, the IH 210 must never be used in areas where there is a
risk of explosion.
• Do not expose the heater to high humidity.
• Never operate the IH 210 without a yoke in position.
• Do not modify the IH 210.
• Use proper handling equipment when lifting heavyworkpieces.
• Avoid contact with hot workpieces. Wear the supplied heatresistant
gloves to handle hot workpieces.

20 Induction Heater IH 210 © simatec ag
1 Introduction
The simatec IH 210 induction heater is designed to heat bearings that are
mounted with an interference fit onto a shaft. The heat causes the bearing
to expand, which eliminates the need to use force during installation.
A 90°C (194°F) temperature difference between the bearing and shaft is ge-
nerally sufficient to enable installation. At an ambient temperature of 20°C
(68°F), the bearing must therefore be heated to 110°C (230°F).
1.1 Intended use
The IH 210 has been designed to heat rolling bearings. However, other
metal workpieces that form a closed circuit can also be heated. Examples
of acceptable workpieces include bushings, shrink rings, pulleys, and
gears. All bearings that fit over the inductive coil and between the vertical
supports with the sliding yoke in place can be heated using the IH 210.
In addition, smaller bearings can be placed over either of the two standard
yokes. See the illustrations at the beginning of this manual for examples.
1.2 Principle of operation
The IH 210 generates heat by
means of a large electrical current
that is magnetically induced in
the workpiece by a coil within the
heater. The high voltage, low
current electricity flowing through
the large number of windings in
the inductive coil induces low
voltage, high current electricity in
the workpiece. Because the
workpiece has the electrical
characteristics of a coil with a
single, short-circuited winding,
the high current generates heat
within the workpiece. Because
the heat is generated within the
workpiece, all of the heater
components remain cool.

© simatec ag Induction Heater IH 210 21
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1.3 Distinguishing feature
The distinguishing feature of the IH 210 induction heater is the location
of the workpiece at the same position on the core as the inductive coil.
This design improves efficiency, resulting in less power consumption and
faster heating, which reduces the cost to heat each bearing.
2 Description
The operation of the heater is controlled by the internal electronics in
either of two modes. The operator can either select the desired
temperature of the bearing in TEMP MODE or set the length of time
that the bearing will be heated in TIME MODE. The power level can be
adjusted in steps of 20% for slower heating of sensitive workpieces
(for example, bearings with C1 or C2 clearance).
2.1 Components
The IH 210 induction heater contains a U-shaped iron core with an
inductive coil surrounding one of the vertical supports. Internal electronics
control the operation of the heater. A sliding yoke on the top of the
vertical supports allows the workpiece to be placed onto the heater.
To accommodate smaller workpieces, a small yoke is also provided.
A temperature probe is also included with the heater. Heat-resistant
gloves are also included.

22 Induction Heater IH 210 © simatec ag
2.2 Technical data
Voltage (± 9%) 400 V / 50 Hz
440–480 V / 50–50 Hz
575 V / 60 Hz
Recommended circuit protection 50A circuit breaker (200-230V)
32A circuit breaker (400-460V)
25A circuit breaker (500-575V)
Power consumption (maximum) 10.0 kVA (400 V / 50 Hz)
11.5 kVA (440–480 V / 50–50 Hz)
10.4 KVA (575 V / 60 Hz)
Temperature control 0–250°C (32-482°F) in steps of 1°
Probe maximum temperature 250°C (482°F)
Time mode 0–60 minutes in steps of 0.1 minute
Power range 20 – 100% in steps of 20%
Demagnetisation, automatic Residual magnetism < 2A/cm
Overall dimensions 600 x 350 x 420mm
Area between supports 250 x 250mm
Coil diameter 135mm
Weight (with yokes) 75kg
Workpiece maximum weight Bearing 300kg, solid component 150kg
Maximum heating temperature approx. 400°C (752°F)
Standard yoke dimensions 70 x 70 x 420mm (for Øof 100mm)
40 x 40 x 420mm (for Øof 60mm)
3 Installation of mains plug
Due to the many types of mains plugs, no mains plug is supplied with
the IH 210. A qualified electrician must install a suitable mains plug.
The correct supply voltage is shown in section 2.2.
The wires should be connected as follows:

© simatec ag Induction Heater IH 210 23
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4 Preparation for use
• Place the IH 210 in the horizontal position on a stable surface.
• Connect the mains plug to a suitable mains supply.
• For workpieces with an internal diameter (>135mm) large enough to fit
over the inductive coil, follow these steps:
- Place the workpiece over the inductive coil using appropriate
lifting equipment.
- For best performance, adjust the position of the workpiece so
that the inductive coil is in the centre.
- If the sliding yoke is not installed on the IH 210, follow the
steps shown in the illustrations at the beginning of this manual.
Remove the protective film from the bright underside of the
sliding yoke before the first use.
- Slide the sliding yoke to the right so that it completely covers the
top of both vertical supports.
• For workpieces that do not fit over the inductive coil, follow these steps:
- Choose the larger of the two yokes that fit through the internal
diameter of the workpiece.
- If necessary, remove the sliding yoke from the IH 210.
- Verify that the protective film has been removed from the
underside of the small yoke if it is to be used for the first time.
- Slide the workpiece onto the yoke that you have selected.
- Position the yoke on the IH 210 with the bright underside
resting evenly on the two vertical supports.
• If you will use TEMP MODE, plug the temperature probe into the
connector on the left side of the heater. Place the magnetic end of
the probe on the inner ring of the bearing or on the innermost
surface of the workpiece.
• Switch the IH 210 on using the power switch on the left side.
• Observe the self-test of the display and signal tone.
Colour of IH 210 wire Mains supply terminal
yellow/green (green) Protection earth (PE)
brown („1“ or black) Phase 1 (L1)
blue („2“ or white) Phase 2 (L2)
Connect the IH 210 to only two of the three phases. Verify that the
correct cicuit breaker is installed. See section 2.2 for circuit breaker
specifications.

B
A
24 Induction Heater IH 210 © simatec ag
5 Operation
5.1 Function of displays
A) The main display shows the selected time or temperature for heating.
Display Indication
t time in minutes
°C temperature in degrees Celsius
°F temperature in degrees Fahrenheit
B) The power display shows the selected power setting.
Display Indication
• 20% power
•• 40% power
••• 60% power
•••• 80% power
••••• 100% power
5.2 Function of buttons
Button Function
POWER Press to adjust the power in steps of 20%.
The selected power is indicated on the power display.
MODE Press to switch between TIME MODE and TEMP MODE.
UP (+) Press to increase the value shown on the main display.
DOWN (-) Press to decrease the value shown on the main display.
START/STOP Press to start or stop the heater. The LED on the
START/STOP button is lit when the heater is heating and
flashes during temperature measurement.

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5.3 Temp mode
• If the main display shows ‘t’, press MODE to select TEMP MODE.
The main display shows °C or °F in TEMP MODE.
• The selected temperature is shown on the main display. The default
temperature for bearings is 110°C (230°F). If a different temperature is
desired, press UP or DOWN to adjust the temperature in steps of 1°.
It may be desirable to heat bearings to temperatures above 110°C
(230°F) for increased mounting time. Consult the bearing specifications
to determine the maximum permitted temperature. Always ensure
the bearing doesn‘t lock due to an excessive expansion of the inner
ring compared to outer ring. See section 5.8.
• Spherical Roller Bearings (SRBs) are subjected to a special
heat treatment. These bearings can be operated at temperatures as
high as 200°C (392°F). Heating these bearings above 110°C (230°F) will
not cause any damage as long as the bearing is still able to rotate. For
other bearings, a temperature of 125°C (257°F) must not be exceeded
unless otherwise specified.
• Press POWER to select the power level. Use the guidelines in
section 5.8 to determine the correct power setting.
• Press START/STOP to start the heater. The main display shows the
current temperature of the workpiece.
• When the selected temperature has been reached, the heater
demagnetises the workpiece, switches off, and generates an
acoustic signal for 10 seconds or until START/STOP is pressed.
• Press START/STOP to stop the heater.
• Remove the workpiece with proper handling equipment.
• If the workpiece remains on the heater, the heater will start again
when the temperature of the workpiece drops 10°C (18°F). Press
START/STOP to stop the heater and demagnetise the workpiece.
• The IH 210 is now ready to heat another workpiece with the
same settings.

26 Induction Heater IH 210 © simatec ag
5.4 Time mode
• If the main display shows °C or °F, press MODE to select TIME MODE.
The main display shows ‘t’ in TIME MODE.
• Press UP or DOWN to adjust the time in steps of 0.1 minute.
• Press POWER to select the power level. Use the guidelines in
section 5.8 to determine the correct power setting.
• Press START/STOP to start the heater. The main display shows the
time that remains.
• When the time has elapsed, the heater demagnetises the workpiece,
switches off, and generates an acoustic signal for 10 seconds.
• Press START/STOP to cancel the acoustic signal and stop the heater.
• Remove the workpiece with proper handling equipment.
• The IH 210 is now ready to heat another workpiece with the
same settings.
5.5 Temperature measurement
When the heater is not operating, the temperature of the workpiece can
be measured by pressing MODE and START/STOP at the same time.
The LED on the START/STOP button flashes during temperature
measurement. Press START/STOP to cancel temperature measurement.
5.6 Change of temperature unit
Press MODE and UP at the same time to switch between °C and °F.
The temperature unit setting remains the same even after disconnection
from mains power.
5.7 Demagnetisation
The workpiece is automatically demagnetised when heating is complete.
Demagnetisation will not occur if the power is interrupted or the main
switch is switched off. To use the IH 210 for demagnetisation only,
select TIME MODE and set the time to 0.1 minute (6 seconds).

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5.8 Power level selection
When heating bearings with an induction heater, most of the heat will
be generated in the inner bearing race. The heat will then be transferred
through the bearing. It is therefore important that bearings with small
internal clearance or slight preload are heated slowly. Slow heating
ensures that the bearing expands evenly, thereby preventing damage to
the bearing.
The shape, weight, size, and internal clearances all affect the amount of
time required to heat a bearing. The large variety of bearing types
precludes the possibility of providing a specific power level setting for
each type. Instead, the following guidelines are provided:
• For sensitive bearings (including bearings with C1 or C2 internal
clearance) or bearings with brass cages, do not exceed 40% power
when using the small yoke or 60% power when using the sliding yoke.
• When using the small yoke, never exceed 60% power.
6 Safety features
The IH 210 is equipped with the following safety features:
• Main switch with overcurrent circuit breaker
• Automatic overheating protection
• Automatic current control
• In the TEMP MODE the heater will switch off if the temperature probe
does not register a temperature increase of 1° every 15 seconds.
To increase the interval to 30 seconds, press MODE and DOWN at
the same time.

28 Induction Heater IH 210 © simatec ag
7 Troubleshooting
A system fault will be indicated by an acoustic signal and one of the follo-
wing fault codes on the main display:
Display Fault Action
E01 E General system failure Return heater for repair.
E02 E Memory failure Return heater for repair.
E03 E Overheated coil Wait until the inductive coil cools.
E04 E not in use
E05 E Temperature increase
of less than 1° every 15
seconds (or 1° every 30
seconds)
Check the temperature probe
connection. If the connection is OK,
select the 30 second interval as
described in section 6 or operate the
heater in TIME MODE.
E06 E Temperature probe not
connected (or defective)
Check the temperature probe.
E07 E Failure during current
measurement
Return heater for repair.
E08 E Failure during communi-
cation with power printed
circuit board
Return heater for repair.
E09 E Overheated printed circuit
board
Wait until the printed circuit board
(PCB) has cooled down.

© simatec ag Induction Heater IH 210 29
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8 Spare parts
Art. No. Description
190.1005 IH 090/210-P Power print 400-575V/50-60Hz
190.1402 IH 210-P/200V Power print 200-230V/50-60Hz
190.1401 IH 210-C Coil 400-460V/50-60Hz
190.1409 IH 210-C/200V Coil 200-230V/50-60Hz
190.1410 IH 210-C/500V Coil 500-575V/50-60Hz
190.7402 IH 210-CP Control print 400-460V
190.7401 IH 210-CP/200V Control print 200-230V
190.7405 IH 210-CP/500V Control print 500-575V
190.7403 IH 210-H Heating pad incl. sealing
190.1403 IH 210-S Main switch 25A/400-460V
190.1411 IH 210-S/200V Main switch 50A/200-230V
190.1412 IH 210-S/500V Main switch 20A/500-575V
190.1408 IH 210-Y100 Yoke 70 x 70 x 420mm (for bearings
with minimum 100mm bore)
190.1405 IH 210-Y80 Yoke 55 x 55 x 420mm (for bearings
with minimum 80mm bore)
190.1404 IH 210-Y60 Yoke 40 x 40 x 420mm (for bearings
with minimum 60mm bore)
190.7404 IH 210-YH Yoke roller housing
190.1406 IH 210-YS Set support yoke 70 x 70 x 150mm
190.1001 IH P2 Temperature probe, K type

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