NSK IHN800 User Manual

USER MANUAL

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INDUCTION HEATER IHN800

Table of Contents

Chapter �� Page

Safety Recommendations ��3

1 Introduction ��3 1�1 Intended Use ��3 1�2 Principle of Operation ��4

2 Description ��4 2�1 Components ��4 2�2 Technical Data ��5

3 Installation of Mains Plug ��5

4 Preparation for Use ��6

5 Operation ��7 5�1 Function of Displays ��7 5�2 Function of Buttons ��7 5�3 Temp Mode ��8 5�4 Time Mode ��8 5�5 Temperature Measurement ��9 5�6 Change of Temperature Unit ��9 5�7 Demagnetisation ��9 5�8 Power Level Selection ��9

6 Safety Features �� 10

7 Troubleshooting �� 10

8 Spare Parts �� 11

2

Safety Recommendations

› Because the IHN800 generates a magnetic ﬁeld, people

wearing a pacemaker must not be within 5 m (16 ft) of the IHN800 during operation� Electronic equipment, such as wrist watches, may also be affected�

› 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 IHN800 and the workpiece� This is not dangerous to human beings and will not cause damage to the IHN800 or the workpiece� However, the IHN800 must never be used in areas where there is a risk of explosion�

› Do not expose the heater to high humidity� › Never operate the IHN800 without a yoke in position� › Do not modify the IHN800� › Use proper handling equipment when lifting heavy

workpieces�

› Avoid contact with hot workpieces� Wear the supplied

heat resistant gloves to handle hot workpieces�

1 Introduction

The IHN800 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 generally 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 IHN800 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 IHN800� In addition, smaller bearings can be placed over the sliding yoke� See the illustration at the beginning of this manual for example�

3

1.2 Principle of Operation

The IHN800 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�

2 Description

The heating cycle is electronically controlled either in a TIME MODE, where the heating time is selected, or in a TEMP MODE where the desired temperature is selected�

The heater can further be run on 50% capacity when small yokes are used or when there is a risk for too quick heating of sensitive workpieces (e�g� bearings with C1 or C2 clearance)�

2.1 Components

The induction heater consists of an U-shaped iron core with a large induction coil on one of its legs� The control electronics sits in a separate control box on top of the heater�

The temperature is controlled by means of a magnetic probe�

4

2.2 Technical Data

IHN800

Voltage (± 9%): 3 ~ 400 – 575V / 50 – 60Hz* Recommended circuit protection 63A circuit breaker Power consumption (maximum) 24kVA Temperature control 0 – 250°C (32 – 482°F) in steps of 1°C (2°F) Probe maximum temperature 250°C (482°F) Time mode 0 – 60 minutes in steps of 0�1 minute Power range 50 – 100% Demagnetisation, automatic Residual magnetism < 2A/cm Overall dimensions 750 x 400 x 935mm Area between supports (wxh) 330 x 355mm Coil diameter 186mm Weight (with yokes) 300kg Workpiece maximum weight 1200kg Maximum heating temperature Approx� 400°C (752°F) Standard yoke dimensions 100 x 100 x 570mm (for Ø of 142mm)

* Each bearing heater family has several voltage options. Please refer to the type plate on the heater body to determine the actual operating voltage.

3 Installation of Mains Plug

Due to the many types of mains plugs, no mains plug is supplied with the IHN800� A qualiﬁed electrician must install a suitable mains plug� The correct supply voltage is shown on the type plate / underside of the heater�

The wires should be connected as follows:

Color of IHN800 Wire Mains Supply Terminal

Yellow/green Protection earth (PE) Brown Phase 1 (L1) Blue Phase 2 (L2)

Connect the IHN800 to only two of the three phases� Verify that the correct circuit breaker is installed� See section 2�2 for circuit breaker speciﬁcations�

5

4 Preparation for Use

› Place the IHN800 in the horizontal position on a stable surface�

› Connect the mains plug to a suitable mains supply�

› For workpieces with an internal diameter (>186mm) 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� › 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, these should be heated on the horizontal yoke�

› 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 IHN800 on using the power switch on the left side�

6

5 Operation

5.1 Function of Displays

A

B

A) The main display shows the selected time or temperature for heating:

Display Indication

t Time in minutes °C Temperature in degrees Celsuis °F Temperature in degrees Fahrenheit

5.2 Function of Buttons

B) The power display shows the selected power setting:

Button Function

POWER Control lamp for main switch on TIME TIME MODE TEMP TEMP MODE BEARING BEARING MODE – recommended heating temperature for bearings of 110°C (230°F) is automatically selected START/STOP To start and stop heating ON/OFF Press to start or stop the heater 50% Power reduced to 50% 100% Full capacity

7

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, adjust the temperature on the main display�

› 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 does not lock due to an excessive expansion of the inner ring compared to outer ring� See section 5�8�

› All 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 the 50% key to reduce the POWER to 50%� 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 IHN800 is now ready to heat another workpiece with the same settings�

5.4 Time Mode

› Select TIME MODE� The main display shows “t” in TIME MODE�

› Set desired heating time by adjusting on the main display�

› Press 50% to reduce the POWER to 50%� 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�

8

› 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 IHN800 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 0 and TEMP 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 Units

Press 0 and BEARING 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 IHN800 for demagnetisation only, select TIME MODE and set the time to 0�1 minute (6 seconds)�

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 and when

using the small yoke, reduce the power to 50%�

9

6 Safety Features

The IHN800 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°C (2°F) every 30 seconds� To increase the interval to 60 seconds, press MODE and DOWN at the same time�

7 Troubleshooting

A system fault will be indicated by an acoustic signal and one of the following fault codes on the main display:

Display Fault Action

E00 E Electronic failure Return heater for repair E01 E Electronic failure Return heater for repair E02 E Electronic failure Return heater for repair E03 E Overheated coil Wait until the inductive coil cools

E04 E

E05 E

E06 E Temperature probe not connected (or defective) Check the temperature probe E07 E Failure during current measurement Return heater for repair

Selected time/temperature out of range

Temperature increases of less than 1°C (2°F) every 30 seconds (or 1°C (2°F) every 60 seconds)

Re-program

Check the temperature probe connection� If the connection is OK, select the 60 second interval as described in section 6 or operate the heater in TIME MODE�

10

8 Spare Parts

Description Part Number

Spare protective gloves IHNGLOVES Spare temperature probe for IHN800 IHNP1SENSOR Spare yoke 65 x 65 x 570mm for IHN800 IHN800-Y1 Spare yoke 100 x 100 x 570mm for IHN800 IHN800-Y2 Spare support yoke 100 x 100 x 150mm for IHN800 IHN800-YS1 Spare support yoke 100 x 100 x 370mm for IHN800 IHN800-YS2

11

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NSK IHN800 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Safety Recommendations