Timken VHIN-G2-10 User manual

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Induction Heaters
VHIN-G2-10, VHIN-G2-35, VHIS-G2-75
VHIS-G2-100, VHIS-G2-150, VHIS-G2-200
VHIS-G2-400, VHIN-G2-600, VHIN-G2-800
USER MANUAL

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CONTACT
The Timken team applies their know-how to improve the reliability and performance of machinery
in diverse markets worldwide.
The company designs, makes and markets hight-performance mechanical components,
including bearings, belts, brakes, clutches, chains, couplings, gears and related mechanical power
transmission products and services.
www.timken.com
Machine ID and certication: See machine plate
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.
• Vériez 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
modications.
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.

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CONTENTS
Foreword ......................................................................................................................................................... 5
1. About the user manual ............................................................................................................................. 5
1.1 Availability .......................................................................................................................................................................................... 5
1.2 Legal guidelines .............................................................................................................................................................................. 5
1.3 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 ........................................................................................................... 13
6.The magnetic temperature sensor ....................................................................................................... 14
7. Method of operation............................................................................................................................... 15
7.1 Heating a hanging workpiece ............................................................................................................................................... 16
7.2 Heating a horizontal workpiece............................................................................................................................................ 17
7.3 Maximum weights ....................................................................................................................................................................... 17
8. Operation.................................................................................................................................................. 18
8.1 Heating in temperature mode (default setting)........................................................................................................... 18
8.2 Heating in time mode ................................................................................................................................................................ 19
8.3 Workpiece installation................................................................................................................................................................ 19
8.4 Error message ................................................................................................................................................................................. 19
8.5 Switching between Celsius and Fahrenheit ................................................................................................................... 19
9. Cleaning, maintenance and troubleshooting .................................................................................... 20
10.Technical data and accessories ........................................................................................................... 22
10.1 Technical specication VHIN-G2-10 - VHIS-G2-150 .................................................................................................. 22
10.2 Technical specication VHIS-G2-200 - VHIN-G2-800 ............................................................................................... 23
10.3 Machine ID and certication ................................................................................................................................................ 24
10.4 Yokes ................................................................................................................................................................................................. 26
10.5 Scope of delivery ........................................................................................................................................................................ 27
11. Disclaimer ............................................................................................................................................... 28
12. Waste disposal ...................................................................................................................................... 28
13. Certicate of conformity ...................................................................................................................... 29
ENGLISH

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1. ABOUT THE USER MANUAL
1.1 Availability
This user manual is supplied with each device and can also be ordered retrospectively.
1.2 Legal guidelines
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. Timken accepts no liability for any damage or malfunctions if the
device or accessories have been modied or used in an incorrect manner.
1.3 Original user manual
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.
FOREWORD
The Timken G2 induction heating devices 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.
In order to ensure durability in demanding industrial operation, the devices are extremely robust
and reliable.

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2. SAFETY, WARNINGS AND POTENTIAL HAZARDS
2.1 Explanation of the pictograms
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 elds.
Warning of hot surface.
Warning of heavy object.

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2.2 Description of potential hazards
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 eld
Be aware that you are working with an appliance that generates electromagnetic
elds. Keep a distance of 1 metre from the unit after switching on.
These elds can be harmful for persons with active medical aids such as
pacemakers.
These elds 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 eld may inuence
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 eld 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.
Furthermore, it cannot be ruled out that the electromagnetic elds could cause
damage to electronic and magnetic data media. Keep such equipment away from
the induction heater.

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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 superuous objects
from the immediate vicinity of the unit.
• Position any cables, including the power supply ones, 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 Timken 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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2.3 Safety measures to be taken
• 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 tted with the proper plug. This must be tted by a qualied electrician.
• Never use or store an induction heater in a damp environment.
• Only use Timken 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 yoke or component.
• Never use a metal strap to support workpieces or suspend them in the magnetic eld. High
currents could start running through the strap, causing it to heat up.
• Do not hold metal objects near yoke and poles.
• Whilst heating, observe a minimum distance of 1 metre (3.3 ft) from the heater.
• Never remove the induction yoke during heating.
• Do not modify the heater. Never use home-made yokes.
• Always check that the induction yoke 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 yoke.
• In the event that smoke or vapor is emitted from the workpiece during heating, ensure that
there is extraction or sucient ventilation in the workshop. Do not inhale vapours or fumes!
Hazard area
The hazard area of the heating device can represent a danger of death.
WARNING!
Failure to observe the following warnings could create a risk of death
or serious injury.
• Danger of heart stoppage in persons tted with a pacemaker due to the strong
electromagnetic eld. Ensure that persons tted with a pacemaker remain outside the hazard
area of the heating device. Erect barriers and attach clearly visible warning signs, Figure 1.
WARNING!
Failure to observe the following warnings could create a risk of death
or serious injury.
• Danger of death for persons with articial heart valves made from metal, hazard of severe
burns due to heating of implants by the electromagnetic eld, 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.

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2.4 Safety provisions
• The electronic systems switch o automatically if the ambient temperature rises
above 70ºC (158º F).
• 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 eld. At a distance of 1 metre, the magnetic
eld has been reduced to such an extent that it is below the applicable standard
of 0.5mT.
WARNING!
Failure to observe the following warnings could create a risk of death
or serious injury.
• 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 eld may inuence the
proper function of such medical aids.
• For this reason, persons with passive implants are recommended not to enter the
immediate vicinity of the induction heater when it is in operation.
1 m
2
1
3
1. Hazard area, 1 m.
2 Barrier.
3 Flat work surface capable of
supporting load.
Figure 1

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3. INTRODUCTION
3.1 Application
Timken induction heaters are intended for heating bearings, so they can be assembled easily by
means of a shrink t. 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
demagnetised automatically after each heating cycle.
Bearings and workpieces can be heated to a maximum temperature of 240ºC (464°F), except for
the Timken VHIN-G2-10 type where the maximum temperature is set at 150ºC (300°F).
Timken 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. Timken VHIN-G2-10 has a duty cycle of 1,5 hour.
NOTE!
• 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 bearing early damage.
• Do not use a heater for bearings and workpieces that are outside the minimum and maximum
dimensions specied in the technical specications.
• Never switch o the unit with the main switch while it is still heating up.
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
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 eld induces a high current (short-
circuit current) through the bearing, which then becomes hot. After
each heating cycle, the bearing or workpiece is demagnetised.

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4. INSTALLATION
• 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 Timken heater is supplied with yokes, temperature sensor, 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 provided
plug may not t. In such cases, obtain a proper plug. It must be tted by a qualied electrician.
There are dierent tting options depending on the type of cable on the heater:
Fitting options VHIN-G2-10, VHIN-G2-35, VHIS-G2-75 and VHIS-G2-100
Fitting options VHIS-G2-150, VHIS-G2-200, VHIS-G2-400, VHIN-G2-600 and VHIN-G2-800
• 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 briey 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.
400V/450V/500V 2 phase heaters 480V/600V 2 phase heaters
Brown Phase Black Phase
Black Phase Black Phase
Green/Yellow Ground Green Ground
120V/230V 1 phase heaters 120V/240V 1 phase heaters
Brown Phase Black Phase
Blue Zero White Zero
Green/Yellow Ground Green Ground

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5. EXPLANATION OF DISPLAY AND KEYS
Start heating after setting
time/temperature >
Heating in time mode >
Time or temperature up >
<Stop heating / automatic
demagnetisation
<Heating in
temperature mode
<Time or temperature down
<Display: time or temperature

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6.THE MAGNETIC TEMPERATURE SENSOR
• The temperature sensor comes with the heater
and can be reordered as spare part.
• 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 at 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.
NOTE!
• 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. Remove the sensor from the workpiece at the plastic part. Do not
pull the cable.

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7. METHOD OF OPERATION
WARNING!
Failure to observe the following warnings could create a risk of death
or serious injury.
• Use suitable lifting equipment for heavy yokes and workpieces. Ensure proper handling
practices are followed.
• The weight of the workpiece may not exceed the value given in section 7.3 and in the
technical specications. 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 eld. High
currents could start running through the strap, causing it to heat up.
A workpiece can be placed in dierent ways:
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.
Hanging, with yoke through
the workpiece
Horizontal, with workpiece
around the pole
Hanging, with yoke through
the workpiece
Horizontal, with workpiece
around the pole
Horizontal, with workpiece
around the yoke
Horizontal, with workpiece
around the yoke

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7.1 Heating a hanging workpiece
• Place the induction yoke with the bearing on the poles. Make sure that the bare metal side is
positioned straight on the poles.
• Always choose an induction yoke that lls the bore of the bearing as much as possible. You can
even use 2 yokes at the same time. This promotes optimal, fast and even heating.
• Always make sure that the workpiece does not come into contact with the plastic casing of the
heater. When the heating is nished, follow the instructions in reverse order. Use heat-resisant
gloves to move the heated workpiece.
• Make sure that the bare-metal sides are suciently coated with acid-free grease to ensure
optimal contact and avoid vibration.
• Swivel arm models: swivel the yoke open (towards you) until it clicks in the safety positioning
cam. Slide the workpiece over the yoke until it is in the middle. Swivel the yoke back to the pole.

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7.2 Heating a horizontal workpiece
• This is only possible if the bore of the workpiece is large enough to t 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 yoke.
• Make sure that the bare-metal sides are suciently coated with acid-free grease to ensure
optimal contact and avoid vibration.
• Always make sure that the workpiece does not come into contact with the plastic casing of the
heater. When the heating is nished, follow the instructions in reverse order. Use heat-resistant
gloves to move the heated workpiece.
7.3 Maximum weights
Table for maximum permitted weights on the horizontal support and the (swivel) yokes:
Type On
supports
Size of (swivel)yokes (mm)
7 10 14 20 30 40 50 60 70 80 90
VHIN-G2-10 - 1 kg 2 kg 3 kg 5 kg - 20 kg - - - - -
VHIN-G2-35 50 kg 1 kg 2 kg 3 kg 5 kg 10 kg 15 kg - - - - -
VHIS-G2-75 100 kg - 2 kg 3 kg 5 kg 10 kg 15 kg 20 kg - - - -
VHIS-G2-100 150 kg - - - 10 kg 15 kg 25 kg 40 kg 45 kg 50 kg - -
VHIS-G2-150 200 kg - - - 10 kg 15 kg 25 kg 40 kg 45 kg 50 kg - -
VHIS-G2-200 400 kg - - - - - - - 60 kg - 80 kg -
VHIS-G2-400 600 kg - - - - - - - 60 kg - - 80 kg
VHIN-G2-600 800kg -----------
VHIN-G2-800 1600 kg - - - - - - - - - - -
• Keep to these maximum weights and avoid tilting the heater or damaging the supports,
(swivel) yokes or hinge.
NOTE!
• Always handle induction yokes with care. They are damaged easily when dropped, knocked
against something, etc. Store them immediately after use.

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8. OPERATION
There are 2 heating methods:
Temperature mode Time 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.
• 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 Timken range.
8.1 Heating in temperature mode (default setting)
• Position the workpiece and sensor (according to chapters 6 & 7.)
• Switch on the heater. The display shows 100°C. Enter the desired temperature by pressing the‘▲’ or
‘▼’button (by pressing the () button, you can select increments of either 1º or 10º).
• Press‘START’. The heating starts, you will hear a slight humming sound.
• The display shows the current temperature of the bearing. Once the pre-set temperature
has been reached, the display blinks and a clear beep is sounded. Unless you press STOP, the
temperature of the bearing is maintained for 5 minutes, thanks to the thermostat feature.
Heating will restart if the temperature drops by 3ºC. Once the pre-set temperature has been
reached again, the induction heater will sound a clear beep.
• The display blinks during this cycle. After 15 minutes, the induction heater switches o
and sounds a continuous beep. Each time the induction heater stops, it automatically
demagnetises the workpiece.
• The heating process or thermostat feature can be interrupted by pressing‘STOP’.

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8.2 Heating in time mode
• Position the workpiece and sensor (according to chapters 6 & 7.) Only use the sensor if you
want to check the temperature before the countdown has completed.
• Switch on the heater and press‘’. Enter the desired time by pressing‘▲’or‘▼’; by pressing
‘’, you can select increments of either 1 minute or 1 second.
• Press‘START’. The heating starts, you will hear a slight humming sound. Press‘’during
heating to display the current temperature for 3 seconds. The countdown then continues.
• During heating, the pre-set time counts down to 00:00. When 00:00 is reached, the induction
heater switches o. The workpiece is then demagnetised automatically and a loud, continuous
beep sounds. Press ‘STOP’ to switch o the beep.
8.3 Workpiece installation
• After pressing‘STOP’, place the sensor on the side of the pole.
By pressing‘STOP’, the workpiece is demagnetised automatically.
• Wear heat-resistant gloves. Place the yoke with the workpiece on a clean surface. If the heater
has a swivel arm, open it up to the safety positioning cam and slide the workpiece o. Install
the workpiece without delay and prevent it from cooling down.
8.4 Error message
• If no temperature increase of at least 1ºC is measured within the time pre-set by the manufacturer,
the induction heater automatically switches o. The display blinks and shows 4 hyphens (----). An
alternating, clear beep is sounded. Press ’STOP’ to switch o the beep and check whether:
• the sensor has been placed on the workpiece.
• the sensor plug has been inserted in the socket.
(Make sure that the – and + of the plug correspond to that of the socket.)
• the wiring of the sensor has not been damaged.
• the surface area of the sensor is clean.
• the workpiece is within the specications for the heater as listed in chapter 10.
If the sensor is faulty, as a contingency measure, the workpiece can be heated with the time
mode. In this case, the temperature must be measured with an external thermometer.
8.5 Switching between Celsius and Fahrenheit
• The induction heater operates in the temperature units °C or °F.
Follow the procedure below to switch between these two units:
• Press and hold the temperature key for 10 seconds. When pressing, a short beep is sounded.
• After 10 seconds, another short beep is sounded and the display changes from one
temperature unit to the other.
• The heater can now be operated using the newly set temperature unit.

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9. CLEANING, MAINTENANCE AND TROUBLESHOOTING
• Store in a dry place, free from frost and damp.
• Clean with a dry cloth. Never clean with water.
• Keep the bare parts of the poles clean. Lubricate regularly with acid-free grease for better
contact with the yokes and to prevent corrosion.
• Also lubricate the pivots regularly.
If the heater produces a loud vibrating sound:
• Stop the heating cycle
• Are all contact surfaces clean and greased?
• Is the yoke positioned level on the poles?
If this is not the case, follow the instructions below to adjust the yoke.
Models with horizontal swivel yoke:
1. Remove dirt, burrs, etc., from the yoke and poles and grease lightly.
2. Place the yoke on the hinge point and rotate it above the poles.
3. Loosen the socket screws and the bolts on the hinge bushing by about half a turn.
4. Switch on the heater by pressing start. The yoke now sets itself. If necessary, a dead blow
(plastic) hammer may be used.
5. When noise reduces, then tighten all bolts and switch o the heater.