Operating Instructions of Heating Device

consisting of
Electric Induction Mounting Fixture(s)
EIM171148.K159
and
Transformer EFB20.45KVA.400V.50HZ

for inner rings FAG WJ/WJP130X240

Figure: Heating device

1 FAG
FAG Kugelfischer AG & Co. KG
Business Unit Industrial Bearings and Services
Postfach 12 60
D-97419 Schweinfurt
Phone 0 97 21 / 91-1915 (international: +49 97 21 91 1915)
Fax 0 97 21 / 91-3809 (international: +49 97 21 91 3809)
Internet: www.fis.de
E-Mail: [email protected]

These operating instructions including all their parts are protected by copyright.
Utilisation of any kind which has not been expressly admitted by the copyright law requires the
prior consent of FAG Kugelfischer.
This applies in particular to reproductions, adaptations, translations, microfilming and to storage
and processing with electronic systems.

File: D_Kleinspannung_Okt03_englisch.doc, 27.10.2003

Page 2
Contents
Page
Contents........................................................................................................................ 3
1. Field of application .............................................................................................. 4
2. SAFETY PRECAUTIONS................................................................................... 5
2.1 General safety precautions............................................................................. 5
2.2 Safety precautions concerning electric current ............................................... 5
2.3 Special safety precautions concerning the device ........................................... 6
2.4 Further guidelines.......................................................................................... 6
3. Standard scope of delivery ................................................................................... 7
3.1 EIM............................................................................................................... 7
3.2 Transformer................................................................................................... 7
3.3 Further accessories ........................................................................................ 8
3.4 Required accessories ..................................................................................... 8
4. Installation ........................................................................................................... 9
4.1 Establishing a water connection..................................................................... 9
4.2 Establishing the main connection on the primary side .................................... 9
4.3 Establishing the main connection on the secondary side............................... 10
5. Operations.......................................................................................................... 11
5.1 Installing the EIM........................................................................................ 11
5.2 Controls....................................................................................................... 12
5.2 Operations ................................................................................................... 14
5.3 How to determine the required pre-heating time .......................................... 18
6. Breakdowns ....................................................................................................... 20
7. Maintenance, repair............................................................................................ 20
8. Technical data .................................................................................................... 21

Page 3
1. Field of application
"EIM“ electrical induction mounting fixtures are intended for heating or demagnetizing
cylindrical roller bearing inner rings and other steel parts of rotational symmetry.

The application range of the EIM is described here:

• Heating of the inner ring of a cylindrical roller bearing or a needle roller bearing for mounting
or dismounting.
• Mounting or loosening the driving fit: Special type and/or dimensions.

The outside diameter of the workpiece must be cylindrical.

The gap between EIM and the workpiece should be max. 1% of the outside diameter of the
workpiece.
The heating is effected under time-control.

Cross-sections that can be heated with EIM:

Cross-sections that cannot be heated with EIM:

Page 4
2. SAFETY PRECAUTIONS
2.1 General safety precautions
Inspect all components for possible transport damage immediately. If any such damage is detected,
file complaints to the forwarding agent without delay.

Prior to operational start-up study the operating instructions thoroughly.

Observe safety precautions in particular. They are related to danger to the life and limb of persons:
DANGER = high potential injury risk
WARNING = potential of injury risk

CAUTION = danger of damaging the device or the workpiece

• Use the device only for the scope of application according to chapter 1!
• Prior to operational start-up and switching-on:
- Power supply and temperature control: check lines and fittings for damage and
safe electrical connection.
- Check water cooling system for: function and leakage
• FAG shall not be held liable for any damage resulting from incorrect handling or any other use
which does not comply with the described purpose.
• The device and accessories must not be modified, in particular the cable of the secondary
electric circuit
• Use original spare parts only
• These operating instructions are only intended for qualified staff who
- have been trained in dealing with rolling bearings, and have for instance skills acc. to the
FAG brochure "Mounting and Dismounting of Rolling Bearings“, publication No.
WL 80 100/3 EA
- have been trained in dealing with the device
- have been familiarized with all safety precautions
(Risk of reduction of the service life and/or damage to the rolling bearing)!

2.2 Safety precautions concerning electric current

• Electrical devices are designed according to the EN 60204-1 standard. Any control and repair
work should only be carried out by authorised electricians in accordance with the applicable
safety regulations. (Danger due to electric current!).
• Connection to current supply according to circuit diagram is only permitted for authorized
electrical specialists:
- The indications on the product label of the machine determine the power ratings
- Local regulations should be observed (in Germany: VDE regulations).
• Never use or store the device in wet or damp surroundings.
• In case of malfunction, inform the manufacturer.
• Never damage, drive over or kink current-carrying cables. If necessary, have these immediately
repaired by electrical specialists as mentioned above.
• Terminal strips:
- to be kept bright
- must never be bridged (danger of short-circuit)
- clamping screws to be tightened to avoid short-circuits (not applicable for plug-in couplings).
Page 5
2.3 Special safety precautions concerning the device

EMERGENCY-STOP function:
Main switch OFF disconnects the power supply to the system.
The main switch is located at the rear of the transformer.

DANGER !
• Use protective gloves (Danger of burning your hands with the hot workpiece).
• Use a crane to lift heavy workpieces ! (Risk of injury if load drops).
• The strong magnetic field generated by the device can have a negative influence on:

• Pacemakers

• Metal implants, e. g. hip joints

• Watches
• - Magnetic strips (e.g. cheque cards).
- Electromagnetic data carriers (e. g. disks).
- Electronic circuits (e. g. ABS systems, measuring instruments, electronic injection systems).
- Other electronic devices and systems.
The safety distance is 2 metres.

• Prevent unauthorized use of the system (pull key out of the stand-by switch)!
The operator is responsible for ensuring that no unauthorised person can put the system into
operation.
• Do not bring metal parts into the immediate proximity of the device (danger due to heating
watches, tools!). Non-metallic parts are not heated up.
• Never use the device in locations wherein there is explosion hazard.
• Only preheat a bearing up to max. 120°C (danger of damaging the bearing!)
• Subsequent to dismounting and mounting, the workpiece must be demagnetized with the aid of
the heating device (danger of reduction of the service life and/or damage to the rolling bearing
as a result of adhering metal chips)

2.4 Further guidelines

• Dispose of auxiliaries containing oil properly
(e. g. convey cleaning rags to hazardous waste plant).

Page 6
3. Standard scope of delivery
Heating device (low-tension system) and operating instructions.
Short symbols, e.g.:
EIM171148.K159
EIM Electrical Induction Mounting Device
171148 Drawing number
K K = low-voltage device (S = special device)
159 Diameter of the bore of the EIM in mm

3.1 EIM

EIM = electric induction mounting fixture = workpiece-specific coil.

These are water-cooled hollow copper windings.

Project EIM Workpiece Number of cables /

cross section
1305 171148.K159 WJ/WJP130X240 2 x 3 x 70 mm²

3.2 Transformer

SERIAL NUMBER EFB03/3

Short symbol for the single-phase dry-type transformer included in the standard scope of delivery ,
e. g.:
EFB20.45KVA.400V.50HZ
EFB20. Type of the transformer
45KVA. Power in kVA
400V. Primary voltage in V
50HZ Primary frequency in Hz

Cable lengths
Secondary cable: 3 m
Temperature monitoring: 4 m
Solenoid valve: 10 m

Further technical data: see chapter 8.

Page 7
3.3 Further accessories
• The sensor with cable for temperature monitoring
aborts the heating procedure once the admissible maximum temperature of the coil is exceeded.
• Solenoid valve with cable intended to supply cooling water to the EIM.
The heating procedure starts 10 seconds after the solenoid valve has been opened.
60 seconds after completion of the heating procedure, the solenoid valve closes the water intake.
• The cable for the secondary circuit
is a part of the equipment. It should not be modified since it influences the voltage in the
secondary circuit.

3.4 Required accessories

Not included in the standard scope of delivery:
• Crane and tackle for the coil
• Cable for primary circuit:
The local provisions should be observed, e. g. relating to the minimum cross-section and the
length (in Germany: VDE regulations).
The cable for the primary circuit is to be provided by the electric supplier or the customer.
It connects the transformer to the customer's three-phase network.
• Water hose ∅ G½" or G¾" for inlet and outlet
• Recommended: Workpiece-specific auxiliary mounting bush, available from FAG on request
• Stopwatch for measuring the heating time in seconds and in minutes
• Heat-resistant gloves
• Device for measuring the workpiece temperature, e. g. TEMP.MG175830, available from FAG
• Suitable aids for axially mounting and securing the workpiece during shrinkage onto the shaft
journal, e. g. mounting sleeve
• Supply of cooling water and current

FAG publication not included in the standard scope of delivery:

• "Mounting and Dismounting of Rolling Bearings", Publication No. WL 80 100/3 EA
• "FAG Induction Heating Equipment", Publication No. WL 80 107/3 DA

Page 8
4. Installation

4.1 Establishing a water connection

- Connect a ∅ G½" or G¾" water hose for inlet and outlet
- Install a solenoid valve in the water intake
- Connect the cable for the temperature monitoring

1
2

Fig.: Installation of the overall system

1 Solenoid valve
2 Cable for temperature monitoring
3 Water intake
4 Water outlet

4.2 Establishing the main connection on the primary side

CAUTION
Risk of short-circuiting in the event of incorrect connection of the secondary cables (damage to the
transformer).

- Connect the cable for the primary circuit to the terminals of the transformer.
- Connect the cable for the primary circuit to the power supply.
- Carry out the safety inspections (in Germany: VDE regulations,
e. g. loop impedance and cut-off conditions)

Page 9
4.3 Establishing the main connection on the secondary side
CAUTION!
Risk of short-circuiting in the event of incorrect connection!

- Clean the terminal strip for the secondary cable thoroughly.

- Connect EIM and transformer by means of the secondary cable.
Always connect Identical colour markings (yellow to yellow and green to green).

To do this, there are two options:

4.3.1 Secondary connection by means of copper joint pieces (early EFB20…models, EFB 33…
and over)
- Connect the secondary cable to the copper joint piece on the transformer.
- Tighten clamping screws.
green yello
w

Fig.: Copper joint pieces

4.3.2 Secondary connection by means of a quick-catch plug connector (only EFB20…)

- Connect the plug connector to the cable of the EIM to the female connectors on the
transformer.
green yello
w

Fig.: Quick-catch plug connector

Page 10
5. Operations
CAUTION!
Prior to initial start-up and switching on:
- Check power supply and temperature monitoring: Cable and terminals
- Check water cooling: Function and tightness

CAUTION!
To handle heavy workpieces: Use crane.

CAUTION!
Subsequent to dismounting and mounting, the workpiece must be demagnetized with the aid of the
EIM (danger of reduction of the service life and/or damage to the rolling bearing as a result of
adhering metal chips)

Wipe grease and oil off the coils and workpieces.

5.1 Installing the EIM

Place rings smaller than approx. ∅400 mm into the EIM

Place light rings manually into the upright EIM.

Always mount and dismount rings larger than approx. ∅400 mm by means of the auxiliary
mounting bush
See fig.:
1. Mount auxiliary mounting bush onto the shaft journal.
2. Position rings and EIM onto the auxiliary mounting bush

Shaft journal EIM Auxiliary mounting bush

Page 11
5.2 Controls

6
7

Fig.. Front of the transformer:

1 Ampere meter: Shows the power consumption on the primary side

2 Time relays: See next page
3 Pilot lamp: Power supply
4 Controls : ON: starts the pre-heating time
OFF: interrupts the power supply (pre-heating time) (= EMERGENCY STOP function)
5 Selector: E = Demagnetization
A1 = Pre-heating for mounting
A2 = Pre-heating for dismounting
6 Stand-by switch: This key-switch protects the EIM against unauthorized use
(turn left – press-in – turn right)
7 Connection: Temperature monitoring
8 Terminal strip: Secondary cable

On the rear: Main switch power supply (= EMERGENCY STOP function)

Page 12
Time relays for setting the pre-heating time
The time relays on the photo shows a pre-heating time of 1.2 minutes (= 1 minute, 12 seconds).

- small rotary knob preselects the time range: 3 s / 30s / 3 min / 30 min / 3 h / 30 h
- large rotary knob and pointer: adjust pre-heating time acc. to the preselected time range

- black pointer indicates the pre-heating time

- red pointer returns to zero

Secondary voltage 20...40 V in steps of 5 Volt

Lines A1 and A2 are reversible (on the rear of the transformer).
The delivery condition is displayed on grey ground. Recommendations: see chapter 6.

Selector position E A1 A2
Line reversible to [Volt] 25 35
20
30 40

Page 13
5.2 Operations

5.2.2 Operations

Contents: a) Dismounting
a1) Pre-heating
a2) Demagnetizing
b) Mounting
b1) Pre-heating
b2) Demagnetizing

a) Dismounting

a1) Pre-heating for dismounting

1. Admissible temperature of the workpieces (shaft journal and ring): max. 30°C.
Otherwise: Let workpieces cool down
2. Slide coil over the rings to be heated and lock with latches or splines. As a result, the EIM
can be later pulled off the shaft journal together with the ring. The latches and splines are
parts of the EIM.
3. Open cooling water inlet

4. Set selector to A2
5. For dismounting, set the time relay to the desired pre-heating time.

If the pre-heating time is unknown:

Set the time relay to 30 minutes.
Main switch to ON. Key switch to ON.
Apply the temperature measuring device to the workpiece.
Simultaneously: Start the stopwatch. Press the ON key.
Measure on the ring's side face: Once a temperature of 100 – 120 °C has been reached:
Read the stopwatch. Press the OFF key.
Enter the stopped time in the table (see chapter 5.3).
Continue with item 9.

6. Main switch ON
7. Key switch to ON.
8. Press the ON key (pre-heating time is running. Time relay switches the transformer off, the
display is at 0).

9. DANGER !
Use protective gloves (risk of burning your hand on hot workpiece).

Rings smaller than approx. ∅ 400 mm: Pull ring off together with the coil.

Rings larger than approx. ∅ 400 mm: Pulls ring(s) off together with the coil onto the
auxiliary mounting bush.

10. To demagnetize ring(s) ! See next page.

Page 14
a2) Demagnetization after dismounting
11. Place the coil with its horizontal bore on the floor
12. Set selector to "E"
13. Time relay to 300 seconds
14. Main switch ON
15. Key switch to ON.
16. Hold the small ring by hand in front of the coil, so that the axes of coil and ring are vertical
to each other, i. e. at an angle of 90°.
17. Press the ON key.

18. SLOWLY move the ring at a constant speed to 1 to 1.5 meters away from the coil:
Speed about 3 seconds/meter.

19. Press the OFF key. The demagnetization process is completed.

20. If necessary: Check residual magnetism.

Guideline for large rings:

Place the ring on a wooden board in front of the coil. It must have a min. length of 1 meter.
Press the ON key. SLOWLY roll the ring on the board at a constant speed out of the magnetic
field of the coil.

Ring

Coil

Board

Page 15
b) Mounting

The heating device can be also used for mounting rings.

Special devices, e. g. FAG pre-heater of the AWG or HEATER series... are, however, more
convenient to use.

b1) Pre-heat for mounting

Differences to "a1) Pre-heating for dismounting“.

• Admissible temperature of the workpieces (shaft journal and ring): max. 30°C.
Otherwise: Let workpieces cool down
• Turn the selector to A1
• For mounting, set the time relays to the desired pre-heating time.
• If the pre-heating time is unknown:
Spec. temperature for mounting: 80 – 100 °C

• DANGER !
Use protective gloves (risk of burning your hand on hot workpiece).

Rings smaller than approx. ∅ 400 mm: Remove the ring from the coil and mount.
Rings larger than approx. ∅ 400 mm: Slide the ring(s) together with the coil off the auxiliary
mounting bush onto the shaft journal.

• Secure ring(s) axially in order to maintain its (their) position(s) when cooling down, e. g.
striking the inner rings against the shaft journal using a mounting sleeve

• It is essential to demagnetize the ring(s) after mounting ! See below.

Page 16
b2) Demagnetization after mounting
21. Slide the coil over the rings to be demagnetized (do not lock the latches).
22. Main switch ON
23. Key switch to ON.
24. Press the ON key.

25. SLOWLY pull the coil off the rings at a constant speed:
The speed should be about 3 seconds/meter.
The coil should then be moved 1 to 1.5 meters in the axial direction beyond the ring. To
obtain a proper demagnetization, the effect of the magnetic field of the coil on the rings
must be released slowly.

Coil

Rings on shaft journal

26. Press the OFF key. The demagnetization process is completed.

27. If necessary: Check residual magnetism.

Page 17
5.3 How to determine the required pre-heating time

General information on pre-heating temperature and pre-heating time

For mounting, rolling bearings are usually heated to 100 to 120° Centigrade. At a room
temperature of about 20°C, this temperature is adequate for all standard rolling bearing fits.
The pre-heating to extract shrunk-on bearing rings or similar parts must be carried out so quickly
that the shaft journal is only slightly heated and the necessary clearance between the joined parts is
achieved. The pre-heating time is the time after which the shrunk-on parts can be safely pulled off.
The admissible pre-heating time is determined by the moment at which a sufficient clearance for
pulling off just exists.
For the induction FAG mounting fixtures, the temperature is determined after the pre-heating time.

The following diagram contains standard values for the admissible pre-heating time relating to the
inside diameter of the shrunk-on parts:

Figure: Admissible pre-heating time, relating to the bearing bore

0...5: Pre-heating time in minutes
0...1000: Bearing bore in millimeters

Page 18
How to determine the pre-heating time in trial

The pre-heating time should be determined separately for both pre-heating procedures:
a) Pre-heating for dismounting
b) Pre-heating for mounting

During the pre-heating process acc. to chapter 5.2.2 Operations, the heating of the ring should be
recorded by means of a temperature measuring device and a stopwatch:

28. ATTENTION: Initial temperature of the workpieces (shaft journal and ring): max. 30°C.
Otherwise: Let workpieces cool down
29. Set time relays to 300 seconds
30. Apply the temperature measuring device to the workpiece.
31. Simultaneously: Start the stopwatch. Press the ON key.
32. As soon as the required temperature is reached:
Read the stopwatch. Press the OFF key.

Required temperature: Pre-heating for dismounting: 100 – 120 °C

Pre-heating for mounting: 80 – 100 °C

Enter the result in a table and retest later in practice.

The pre-heating time is generally identical for dismounting and mounting.

Project EIM Bearing No. Pre-heating time for

No. dismounting and
mounting (seconds)
1305 EIM171148.K159 WJ/WJP130X240

Page 19
6. Breakdowns
Fault Cause Remedy
Pilot lamp for power supply Power supply on primary Check the fuse of the customer.
does not light up side is interrupted. Check the primary cable for
Pilot lamp is defective damage.
Turn main switch to ON.
Replace pilot lamp.
Pilot lamp for temperature Coil becomes hot and is Open water cock.
monitoring lights up (in the deactivated by thermistor Increase flow volume.
transformer, red LED on A1). protection (A1). Decalcify coil and improve the
System is deactivated. quality of the cooling water
Water does not run although Solenoid valve does not Skilled electrician must check
the water cock is open. open the system.
Coil becomes hot.
Power demand while pre- A2 clamped to 40V On the rear of the transformer:
heating for dismounting is too Clamp A2 to 35V
high
Pre-heating time for the A1 clamped to 25V Clamp A1 to 30V.
mounting is too long

7. Maintenance, repair
Clean after each operations
Entire mounting fixture
Power supply cord

Check regularly for damage

Primary cable
Secondary cable
Cable for solenoid valve
Temperature detector
Protective covers for supply point on the transformer.

Repair defective components immediately!

Check regularly for function

Terminals: Clamping force and contact.
Solenoid valve: Press the ON key, water must escape at the hose end.

In case of a fault on the heating device

Please contact the manufacturer for inspection or repair,
for address see page 2.

Page 20
8. Technical data
Correct indications: see type plate on EIM and transformer.

EIM

Primary voltage Vprim: 400V

Primary current Iprim: see table
Secondary current Vsec: 20...40 V in steps of 5 Volt
Protection: IP23
Vector group: Iio

ON period 20 % related to 1 hour.

Consequently, continuous operations are possible by idle times due to mounting.

Performance of moveable FAG single-phase-dry-type transformers

Name of Cross-section of Intermittent Primary power Ring weight

transformer primary cable performance consumption
(fusing)
FAG mm² kVA A max. kg
EFB 20 3x25 45 120 20
EFB 33 3x35 75 200 35
EFB 50 3x70 110 290 90
EFB 80 3x95 180 475 250
EFB 125 3x150 290 760 750
EFB 125 3x185 400 1000 1200
with fan

The largest transformer EFB 125/1 is adequate to heat inner ring with a weight of 1,200 kg tot he
required mounting temperature within the admissible pre-heating time.

The admissible pre-heating time is the time interval wherein the ring can be dismounted.
That means that the required oversize has been reached without exceeding the max. admissible
pre-heating temperature (120°C for rolling bearing inner rings).
Consequently, a modification of the metal structure is also prevented.

Water demand, approx.: medium-sized coils: 10...15 ltr/min

large coils: 20...25 ltr/min
Check flow volume using a bucket and a stopwatch.

Paint finish of the casing: transformer RAL

RAL 9002 (grey-white) housing
RAL 2002 (blood orange) cover

Page 21
Dimensions and weights of the moveable FAG single-phase dry-type transformers

Name of Dimensions Weight

transformer Depth x width x height
FAG a c b approx. kg
EFB 20 800 660 1150 320
EFB 33 800 760 1192 350
EFB 50 970 760 1192 410
EFB 80 1200 790 1400 640
EFB 125 790
EFB 125 1000
with fan

Weights of the secondary cables

WARNING !
Caution when lifting the secondary cables, they can have a weight of up to 60 kg
(risk of injury for the spine).

Dimensions of the EIM included in the standard scope of delivery

See chapter 3.1.

Page 22