FAG PowerTherm
Contents
1. FAG PowerTherm HEATER35 HEATER150 HEATER300 HEATER600 HEATER1200 User manual SCHAEFFLER GROUP INDUSTRIAL 2 Features Initial operation of devices Heating of rolling bearings Troubleshooting Technical data Spare parts Accessories Ordering designations BA 18 FAG PowerTherm Page SarebEuldelll scs ividd emt 3 HEATER S5 tO HEALER 200 3 Scope OF CEN VED 4 SUNCONINGS gt 5 Trolley TOPHEATER 3 005 6 timeo ous 6 Contiguring 5 1502200 255 Seve era vorat s UY 7 Configuring HEATER600 1200 8 Temperature controlled heating 10 Time controlled heating 11 Error messages in the 11 Alignment ot ledges c s et nee ve VERS 12 HEATER c ewan 13 EATER 14 HEATER SOO 15 HEA TERGO Oeren dia oneratus eon Oo ene OH 16 PR 17 HEATERS Juror RN2. 18 tub te ua eod E 19 HEATERS 0O E N E SS 20 HEATERGO OO e A N 21 HEATER VEI SERRE D dob eset es tele adt 22 23 Schaeffler Group Industrial Features Safety guidelines Caution HEATER35 to HEATER1200 Schaeffler Group Industrial Function FAG PowerTherm This manual is valid for the HEATER35 150 300 600 1200 The HEATERS are supplied in appropriate packaging The packaging and the device should be checked immediately for any damage during transit Photograph any damage and inform the carrier without delay It is essential that all instructions in this user manual are observed Operating personnel must be authorised Unauthorised persons should be kept at a distance during heating it may be appropriate to close off the area Safety regulations must be kept ready with the device and observed Heating devices must be operated and stored in dry rooms only otherwise there is a risk of corrosion Remove any contamination and oil residues immediately Ledges must be handled carefully mechanical damage deformation and moisture must be avoided Repairs should only be carried out by FAG Industrial Services FIS or authorised companies Only HEATER genuine spare parts should be used Schaeffler KG assumes no lia
3. BA18 7 FAG PowerTherm Accessory extension pieces For the heating of bearings with a larger cross section place two accessory extension pieces on the vertical posts Figure 7 1 Extension pieces Figure 7 HEATER35 150 300 Extension pieces for larger bearing ms cross sections 141 161 Configuring HEATER600 1200 Caution Grease the ground surfaces of the ledges The vertical ledge must lie flat Work steps see Figure 8 Lift the vertical ledge 3 manually or using hoisting equipment Place the bearing horizontally on the support blocks 2 in the support rails 1 and centre Lower the vertical ledge again until it lies flat Do not tilt or rotate Use support blocks during horizontal positioning Provide additional support for large rolling bearings projecting beyond the support rails The operator console 4 can be rotated 90 degrees to a convenient position D 4 support rails 2 Support blocks 3 Movable vertical ledge 4 Swivelling operator console Figure 8 HEATER600 1200 141177 8 BA18 Schaeffler Group Industrial Lifting fixture for HEATER1200 Ifthe heating devices HEATER600 or HEATER1200 are equipped with a lifting fixture the vertical ledge can be raised and lowered easily via remote control See the separate user manual Figure 9 HEATER1 200 with lifting fixture 141 178 Accessory ledges For optimum heating of workpieces with smaller inside diameters use the cor
4. Group Industrial HEATER150 1 Baseplate 2 Power supply connector 3 Main switch 4 Coil 5 U shaped core 6 Housing cover 7 Slewing ledge Operator terminal 9 Operator circuit board 9 Jack for temperature sensor 1 Capacitor 2 Main circuit board Figure 21 5 HEATER150 Spare parts Ordering designations Designation Ordering designation Temperature sensor HEATER SENSOR Controller HEATER150 ETRONIC Main switch HEATER150 MAIN SWITCH Main circuit board HEATER150 BOARD1 Operator circuit board HEATER150 BOARD2 Thyristor HEATER150 THYRISTOR Display HEATER150 DISPLAY Slewing ledge HEATER150 LEDGE 100 1 Smallest workpiece bore diameter Accessories Ordering designations Designation Ordering designation Support ledges dimensions in mm 1414x350 HEATER150 LEDGE 20 Slewing ledges dimensions mm 2020350 HEATER150 LEDGE 30 3030350 HEATER150 LEDGE 45 40 40 350 HEATER150 LEDGE 60 5050350 HEATER150 LEDGE 70 6060x350 HEATER150 LEDGE 85 Two extension pieces dimensions in mm 70X70X150 HEATER150 ADAPTER150 70X70X 200 HEATER150 ADAPTER200 Clamping temperature sensor HEATER SENSOR CLAMP 1 Smallest workpiece bore diameter Schaeffler Group Industrial BA18 19 FAG PowerTherm HEATER300 1 Baseplate 2 U shaped core 3 Housing cover 4 Support rails 5 Rotation point 6 Slewing ledge 7 Operator terminal 8 Jack for temperature sensor 9 Con
5. material must be suitable for induction heating The workpiece must be of a closed shape Workpiece weight limits must be observed HEATER35 max 35 kg HEATER150 max 150 kg HEATER300 max 300 kg HEATER600 max 600 kg HEATER1200 max 1200 kg Work steps Place the HEATER on a stable flat surface Ensure that the voltage of the power supply matches the voltage indicated on the identification plate Connect to the mains supply If necessary the mains plug should be changed by skilled personnel HEATER35 3 strand cable BROWN live BLUE neutral YELLOW GREEN earth 230 V see rating plate HEATER150 300 600 Mains plug with two phases 400 V see rating plate HEATER1 200 Connect directly in terminal box Figure 2 400 V see rating plate 141 173 BA18 5 Trolley for HEATER300 D 2 M10X12 screws for handle 2 8 M10XM12 screws for castors 3 8 M10 XM12 screws for fixed wheels Figure 3 Assembling the trolley for HEATER300 1 4 M8 X30 screws Figure 4 Fastening HEATER300 to the trolley with screws Positioning of workpieces Caution 1 Optimally used ledge cross section 2 Position of the temperature sensor Figure 5 Optimally used ledge cross section and correct position of the temperature sensor 6 BA18 FAG PowerTherm Mount the trolley handle and wheels using the screws supplied Figure 3 Fasten the heating device to the support surface using four M8x30
6. screws Figure 4 141 174 141 175 Clean the ledges and magnetic temperature sensor Ensure that the inside diameter of the bearing is filled optimally Figure 5 1 The larger the cross section of the ledge that is used the shorter the heating time On rolling bearings position the magnetic temperature sensor as centrally as possible on the end face of the inner ring Figure 5 2 141 158 Schaeffler Group Industrial Configuring HEATER35 150 300 Caution Grease the ground surfaces of the ledges Position the horizontal ledge correctly Work steps see Figure 6 Swivel the horizontal slewing ledge to the side Place the bearing on the circular area above the induction coil or on the slewing ledge 2 Move the slewing ledge back to its original position ground side downwards Two identical bearings can be heated simultaneously on the slewing ledge 2 or one of the accessory ledges The weight limits must be observed Accessory ledges Suitable accessory ledges should be used for smaller bore diameters Remove the slewing ledge from the shaft and position the accessory slewing ledge on the stud Simply place the accessory slewing ledges available for the HEATER35 and the HEATER150 with the ground side downwards on the ground end faces of the two vertical ledges D Induction coil 2 Slewing ledge Figure 6 HEATER35 Configuration identical to HEATER150 300 141 176 Schaeffler Group Industrial
7. 141 192 Spare parts Ordering designations Designation Ordering designation Temperature sensor HEATER SENSOR Controller HEATER600 ETRONIC Main switch HEATER600 MAIN SWITCH Main circuit board HEATER600 BOARD1 Operator circuit board HEATER600 BOARD2 Thyristor HEATER600 THYRISTOR Display HEATER600 DISPLAY Vertical ledge HEATER600 LEDGE 145 Four support rails HEATER600 SUPPORT BLADE Four support blocks HEATER600 BASE PLATE 1 Smallest workpiece bore diameter Accessories Ordering designations Designation Ordering designation Vertical ledges dimensions in mm 30 40 700 HEATER600 LEDGE 45 4040x700 HEATER600 LEDGE 60 5050x700 HEATER600 LEDGE 70 6060700 HEATER600 LEDGE 85 70 70 700 HEATER600 LEDGE 100 8080x700 HEATER600 LEDGE 115 90 90 700 HEATER600 LEDGE 130 Clamping temperature sensor HEATER SENSOR CLAMP 1 Smallest workpiece bore diameter Schaeffler Group Industrial 18 21 FAG PowerTherm HEATER1200 1 Support rails 2 Support blocks 3 Vertical ledge 4 Main circuit board 5 Thyristor 6 Capacitor 7 Jack for temperature sensor Operator terminal 9 Swivelling operator console Operator circuit board 1 Main switch 2 Coils 3 U shaped core Power supply connector Figure 24 HEATER1 200 141 193 Spare parts Ordering designations Designation Ordering designation Temperature sensor HEATER SENSOR Controller HEATER1200 ETRONIC Main switch HEATER1200
8. MAIN SWITCH Main circuit board HEATER1200 BOARD1 Operator circuit board HEATER1200 BOARD2 Thyristor HEATER1200 THYRISTOR Display HEATER1200 DISPLAY Vertical ledge HEATER1200 LEDGE 215 Four support rails HEATER1200 BLADE Four support blocks HEATER1200 BASE PLATE 1 Smallest workpiece bore diameter Accessories Ordering designations Designation Ordering designation Vertical ledges dimensions in mm 60x 60 850 HEATER1200 LEDGE 85 80x 80850 HEATER1200 LEDGE 115 100x100X850 HEATER1200 LEDGE 145 Clamping temperature sensor HEATER SENSOR CLAMP 1 Smallest workpiece bore diameter 22 BA18 Schaeffler Group Industrial Specifications EU Declaration of Conformity Schaeffler Group Industrial Electrical safety IEC 335 1 Class 1 IEC 664 1 Class 1 and Safety Class 1 The heating devices comply with Low Voltage Directive 73 23 EEC and EMC Directive 89 336 EEC EMC emission EN 55011 EN 60555 2 and EN 60555 3 EMC immunity IEC 801 2 IEC 801 3 IEC 801 4 and IEC 801 5 BA 18 23 MATNR 032837534 0000 BA 18 GB D 2007052 Printed in Germany by Frankendruck Schaeffler KG Georg Sch fer Strasse 30 97421 Schweinfurt Germany Internet www fag com E Mail FAGinfo schaeffler com In Germany Phone 0180 5003872 Fax 0180 5003873 From Other Countries Phone 499721 91 0 Fax 49 9721 91 3435 Every care has been taken to ensure the correctness of the information contained in this publicati
9. bility for damage arising from incorrect handling negligence modifications to the heating device or a failure to provide information to third parties The devices are used to heat rolling bearings including sealed or greased bearings for the purposes of easier mounting They can also be used to heat other rotationally symmetrical steel parts such as bushes rings gears etc The permissible heating temperatures for INA and FAG brand bearings are given in the corresponding catalogues For other products the data provided by the manufacturer should be taken as valid The heart of each of the five heating devices is a live electric coil with an iron core primary circuit This induces a high current at low voltage in a short circuited secondary circuit a bearing or round workpiece The part to be mounted is heated quickly the device itself the ledges and non metallic components remain cool After heating the parts are demagnetised and voltage free Safe operation of the device is ensured by means of an integrated temperature cut off switch a current regulator thyristor and an overcurrent protector The devices can be operated continuously without the need for cooling BA18 3 4 BA 18 Scope of delivery HEATER35 HEATER150 HEATER300 Figure 1 HEATER300 TROLLEY HEATER600 HEATER1200 Caution FAG PowerTherm Heating device slewing ledge for bore diameters from 70 mm magnetic temperature sensor metal box
10. ctly positioned 3 minutes HEATER150 Are the temperature sensor 5 minutes HEATER300 600 and power cable intact 10 minutes HEATER1200 Is the bearing workpiece too heavy Is the shape and material suitable for induction heating E10 Electronic system is not Check measuring any zero crossing Are the cable connections of the circuit board correct replace main circuit board if necessary E12 Main power circuit interrupted Check Are all the electronic plug in connections made correctly Is the cable connection of the thyristor to the high voltage circuit board in working order if necessary replace the circuit board and test the device BA18 11 FAG PowerTherm Alignment of ledges The slewing ledge support ledge in HEATER35 and HEATER150 consists of a large number of transformer sheets permanently bonded together HEATER300 600 1200 The slewing ledge and the vertical ledges can be adjusted for example if the device is generating a large amount of noise Work steps Switch off the HEATER using the Start Stop button Ensure that the ground ledge surfaces are smooth and greased Check that the horizontal slewing ledge is laid flat on the vertical ledges With HEATER600 1200 the vertical ledge must fit correctly Switch on the device 1 Screws 2 Slewing ledge Figure 11 HEATER300 Alignment of slewing ledge 141 180 1 Screws 2 Vertical ledge Figure 12 HEATER600 1200 Alignmen
11. minated The heating process can be interrupted at any time using the Start Stop button 3 141 179 Schaeffler Group Industrial Time controlled heating process Caution Interruption of heating Troubleshooting Error messages in the display Danger Display errors actions Schaeffler Group Industrial Work steps see Figure 10 Do not connect the temperature sensor Switch on the power supply main switch see page 18 to page 21 The display will show 110 C Press the button Time display 5 the display 1 will now show 00 00 Use the temperature setting buttons 2 to set the desired heating time up to max 99 min 59 s 99 59 Start the heating process using the Start Stop button 3 The time shown in the display 1 counts down to 00 00 and then triggers an acoustic signal Acknowledge using the Start Stop button 3 and remove the workpiece using safety gloves The heating process can be interrupted at any time using the Start Stop button 3 The display may show the error messages E01 E02 E10 and E12 see table Display errors actions Before opening the device disconnect the power supply Display Error Actions and remedies code E01 Magnetic temperature sensor Check inoperative Is the temperature sensor connected Is the power cable in working order E02 The temperature is increasing Check by less than 1 C within Is the temperature sensor 1 minute HEATER35 corre
12. ng ledge 70X 70X350 Figure 15 HEATER150 141 184 14 BA18 Schaeffler Group Industrial HEATER300 Designation Power consumption Voltage and frequency Current Temperature display Mass Workpiece mass Dimensions WXHXL Designation Heating device Slewing ledge Figure 16 HEATER300 Schaeffler Group Industrial Technical data max 12 8 kVA 200 V to 600 V 50 Hz 60 Hz 32A 50 C to 240 C 75 kg max 300 kg Dimensions in mm 310X880X565 80x 80 490 18 15 FAG PowerTherm HEATER600 Designation Technical data Power consumption max 25 kVA Voltage and frequency 200 V to 600 V 50 Hz 60 Hz Current 63A Temperature display 50 C to 240 C Mass 350 kg Workpiece mass max 600 kg Dimensions in mm Heating device 82011001070 Vertical ledge 100 100x 700 Dimensions WXHxL Designation Figure 17 HEATER600 141 186 16 BA18 Schaeffler Group Industrial HEATER1200 Dimensions WXH xL Figure 18 HEATER1200 Circuit diagram CD Main switch 2 Capacitor 3 Coil 4 Circuit board for high voltage 5 Magnetic temperature sensor 6 Circuit board for low voltage Figure 19 Circuit diagram HEATER150 300 600 1200 Schaeffler Group Industrial Designation Power consumption Voltage and frequency Current Temperature display Mass Workpiece mass Designation Heating device Vertical ledge Technical data max 40 kVA 200 V t
13. o 600 V 50 Hz 60 Hz 100A 50 C to 240 C 850 kg max 1200 kg Dimensions in mm 1050 1500 1270 150 150 850 141 187 The circuit diagram for 1 50 HEATER300 HEATER600 HEATER1200 is identical 141 188 BA 18 17 Spare parts Accessories Ordering designations HEATER35 1 Power supply connector 2 Coil 3 U shaped core 4 Housing cover 5 Slewing ledge 6 Operator terminal 7 Operator circuit board Main switch 9 Jack for temperature sensor Baseplate 1 Main circuit board Figure 20 HEATER35 Spare parts Ordering designations Accessories Ordering designations 18 BA18 FAG PowerTherm 141 189 Designation Ordering designation Temperature sensor HEATER SENSOR Controller HEATER35 ETRONIC Main switch HEATER35 MAIN SWITCH Main circuit board HEATER35 BOARD1 Operator circuit board HEATER35 BOARD2 Thyristor HEATER35 THYRISTOR Display HEATER35 DISPLAY Slewing ledge HEATER35 LEDGE 70 1 Smallest workpiece bore diameter Designation Ordering designation Support ledges dimensions in mm 10 10 280 HEATER35 LEDGE 152 14 14 280 HEATER35 LEDGE 20 Slewing ledges dimensions in mm 25 25 280 HEATER35 LEDGE 35 3030280 HEATER35 LEDGE 452 4040280 HEATER35 LEDGE 60 Two extension pieces dimensions in mm 50 50 120 HEATER35 ADAPTER120 Clamping temperature sensor HEATER SENSOR CLAMP 1 Smallest workpiece bore diameter Schaeffler
14. on but no liability can be accepted for any errors or omissions We reserve the right to make technical changes Schaeffler KG 2007 May This publication or parts thereof may not be reproduced without our permission BA 18 GB D
15. responding accessory vertical ledges Schaeffler Group Industrial BA18 9 Heating of rolling bearings Danger Caution Temperature controlled heating process Self compensating function Interruption of heating Display 2 Buttons for setting the temperature 3 Start Stop button 4 Temperature display 5 Time display Figure 10 Display and control panel 10 BA18 FAG PowerTherm Safety gloves must be worn Before starting the heating process ensure that the horizontal ledge is correctly positioned Connect the temperature sensor and position it correctly Do not heat rolling bearings to more than 120 C Work steps see Figure 10 Switch on the power supply main switch see Figure 24 page 22 The display 1 will show 110 C Set the temperature to a value between 40 C and 240 C rolling bearings max 120 C Start the heating process using the Start Stop button 3 When the selected temperature is reached an acoustic signal sounds and the selected temperature value flashes in the display 1 Acknowledge using the Start Stop button 3 detach the magnetic temperature sensor and remove the workpiece using safety gloves The function operates as follows If the heated part is not removed and its temperature decreases by 5 C the process is repeated up to five times When the selected temperature value flashes in the display the process described above should be ter
16. safety gloves Heating device slewing ledge for bore diameters from 100 mm magnetic temperature sensor safety gloves Heating device slewing ledge for bore diameters from 115 mm magnetic temperature sensor safety gloves Accessories Trolley HEATER300 TROLLEY Figure 1 141 172 Heating device vertical ledge for bore diameters from 145 mm magnetic temperature sensor four support blocks safety gloves Heating device vertical ledge for bore diameters from 215 mm magnetic temperature sensor four support blocks safety gloves The devices are top heavy there is a risk of tilting When transporting with a fork lift truck or crane always pay attention to the fact that due to the copper coil the centre of gravity is located near the top not in the middle Aids must be designed in accordance with the weight of the heating devices Schaeffler Group Industrial Initial operation of devices Safety guidelines Danger Caution 1 Live L1 R 2 No connection 3 Live L2 S 4 Main switch 5 No connection 6 Main switch Figure 2 Terminal box on HEATER1200 Schaeffler Group Industrial HEATER should never be used in rooms with an explosion risk Persons with pacemakers must not use the devices or stay in their vicinity Sensitive devices such as wristwatches information media with a magnetic strip electronic devices etc may be rendered unusable a safe distance of 2 metres must be maintained The
17. t of vertical ledge 141 181 HEATER is still too noisy Work steps see Figure 11 and Figure 12 Switch off the device using the Start Stop button Loosen the screws 1 in the slewing ledge 2 vertical ledge 2 by turn anticlockwise Switch on the device and the ledge should align itself if not use a plastic hammer to assist the process Retighten the screws 1 Switch off the device 12 BA18 Schaeffler Group Industrial Technical data HEATER35 Dimensions WXH xL Figure 13 HEATER35 Circuit diagram CD Main switch 2 Coil 3 Circuit board for high voltage 4 Magnetic temperature sensor 5 Circuit board for low voltage Figure 14 Circuit diagram for HEATER35 Schaeffler Group Industrial Designation Power consumption Voltage and frequency Current Temperature display Mass Workpiece mass Designation Heating device Slewing ledge Technical data max 3 6 kVA at 230V max 2 2 kVAat 110 V 115 V to 240 V 50 Hz 60 Hz 16A 50 C to 240 C 31 kg max 35 kg Dimensions in mm 260 360 420 50 50X280 141 182 18 13 FAG PowerTherm HEATER150 Designation Technical data Power consumption max 12 8 kVA Voltage and frequency 200 V to 600 V 50 Hz 60 Hz Current 32A Temperature display 50 C to 240 C Mass 51 kg Workpiece mass max 150 kg Dimensions WXH XL Designation Dimensions in mm Heating device 260505440 Slewi
18. trol cabinet Main switch 1 Operator circuit board 2 Capacitor 13 Thyristor Main circuit board 5 Coils Figure 22 HEATER300 141 191 Spare parts Ordering designations Designation Ordering designation Temperature sensor HEATER SENSOR Controller HEATER300 ETRONIC Main switch HEATER300 MAIN SWITCH Main circuit board HEATER300 BOARD1 Operator circuit board HEATER300 BOARD2 Thyristor HEATER300 THYRISTOR Display HEATER300 DISPLAY Slewing ledge HEATER300 LEDGE 115 Two support rails HEATER300 BLADE 1 Smallest workpiece bore diameter Accessories Ordering designations Designation Ordering designation Slewing ledges dimensions in mm 20 20 490 HEATER300 LEDGE 30 30 30 490 HEATER300 LEDGE 45 40 40 490 HEATER300 LEDGE 60 5050490 HEATER300 LEDGE 70 6060x490 HEATER300 LEDGE 85 70X70X490 HEATER300 LEDGE 100 Two extension pieces dimensions in mm 8080x150 HEATER300 ADAPTER150 8080x200 HEATER300 ADAPTER200 Trolley HEATER300 TROLLEY Clamping temperature sensor HEATER SENSOR CLAMP 1 Smallest workpiece bore diameter 20 BA18 Schaeffler Group Industrial HEATER600 1 Support rails 2 Support blocks 3 Vertical ledge 4 Main circuit board 5 Thyristor 6 Capacitor 7 Jack for temperature sensor Operator terminal 9 Swivelling operator console Operator circuit board 1 Main switch 2 Coils 3 U shaped core Power supply connector Figure 23 HEATER600
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