Fenix 80 Turbo User manual

FeniX Induction Heaters

User's Manual

Heater 45 Turbo

Heater 60 Turbo

Heater 80 Turbo

by

1/16 FeniX Induction Heaters

PLEASE READ USER'S MANUAL CAREFULLY BEFORE USING THE MACHINE!

Check all parts for any transport damage. Please contact your

dealer/carrier if there is any damage.

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Contents

Chapter Page

1 Safety Recommendations ........................................................... 4

2 General Informations ........................................................... 5

2.1 Applications ....................................................................... 5

2.2 Recomended Operating Environments ........................ 5

3 Technical Data ....................................................................... 6

4 Installation Of Mains Plug ........................................................... 7

5 Preparation For Use ........................................................... 8

6 Operation .................................................................................. 9

6.1 Control Pannel ........................................................... 9

6.2 Power Level ...................................................................... 9

6.3 Magnet Sensor ........................................................... 10

6.4 Operating Modes ........................................................... 10

6.4.1 Temperature Mode ............................................... 11

6.4.2 Time Mode ........................................................... 13

7 Overload Warning .................................................................................. 14

8 Coil Overheated Warning ..................................................................... 15

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1- Safety Recommendations

CAUTION!

• Because of magnetic field,people wearing medical devices like

pacemaker or hearing aid, mustn't be within 5 meters of the machine

during operation.

• Electronic equipments or wristwatches, may also be affected.

• Be sure base panel of the machine cooled down before carrying.

During the operation, base panel may get hot.

• Be sure heated workpiece is not touching to electric cables.

• Follow the instructions at all the time.

• Be certain that you choose correct voltage supply.

• Never operate the machine in explosion risk areas.

• Do not expose the machine to high humidity.

• Never operate the machine without a yoke in position.

• Wear heat resistant gloves to handle hot workpieces.

• Use proper handling equipment when lifting heavy workpieces.

• Do not bring metal objects near to the machine while operation.

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2- General Informations

2.1 Applications

FeniX induction heaters has been designed to heat bearings; moreover, other metal

workpieces that form closed circuit like bushings, flange couplings, shrink rings, pulleys and

gears can be heated. Except special orders, maximum teperature limited to 250 °C .

Caution!

• Generally bearings should not be heated over 110 °C(at an

ambient temperature of 20 °C.

• Exquisite bearings should not be heated over 70 °C, that may couse

damage on the bearing.

• Demagnetization will not occur if the machine unpluged or the

main switch is switched off during operation.

• When the machine operating, and the power is lost and

restored, please select one of the modes and operate the

machine for a while to do workpiece's demagnetisation.

2.2 Recomended Operating Environments

For proper use of the machine, the following chart provides important information

concerning the recommended operating environments, or operating conditions.FeniX

Induction heaters designed for indoor use only.

• Operating Temperature 0ºC to 40ºC

• Operating Humidity 5% to 90%

• Transport/Storage Temperature -20ºC to 60ºC

Warning!: Operating the machine outside of the recommended operating environment

may negatively impact the machine performance, may cause damage to the machine

and will void the warranty!

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3- Technical Data

Model Heater 45 Turbo Heater 60 Turbo Heater 80 Turbo

Power 3,6kVA 6.0kVA 12,2kVA / 7kVA

Voltage 220-240V 380-420V / *220-240V 380-420V / *220-240V

Current 15,6A 15A 31A

Frequency 50hz 50hz 50hz

Yokes

**7 X 7 X 230mm

10 X 10 230mm

25 X 25 X 230mm

45 X 45 X 230mm

**20 X 20 X 300mm

**30 X 30 X 300mm

40 X 40 X 300mm

**50 X 50 X 300mm

60 X 60 X 300mm

**20 X 20 X 430mm

**30 X 30 X 430mm

40 X 40 X 430mm

60 X 60 X 430mm

80 X 80 X 430mm

Heater Control Unit Microprocessor Microprocessor Microprocessor

Turbo Heating Yes Yes Yes

Maximum Bearing Weight 40kg 150kg 300kg

Maximum Workpiece Diameter 350mm 500mm 600

Minimum Workpiece Diameter 10mm 28mm 28mm

Magnet Sensor Yes Yes Yes

FeniX Induction Heater Mass 19kg 38kg 98kg

FeniX Induction Heater Diameters 380 X 200 X 286(mm) 440 X 220 X 379 (mm) 600 X 280 X 528 (mm)

Power Level 5 Levels 5 Levels 5 Levels

Digital Screen Yes Yes Yes

Time Control 0-100*** min. 0-100*** min. 0-100*** min.

Temperature Control 0-250*** ºC 0-250*** ºC 0-250*** ºC

Audio Warning Yes Yes Yes

Automatic demagnetization Yes Yes Yes

Carrying Bag **Yes No No

Warranty 2 years 2 years 2 years

* = If lower voltage is used, the power will be reduced.

** = Optional

*** = Can increase.

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4- Installation Of Mains Plug

Be assured that the voltage supply is correct before operating the machine. Because of

many different types of mains plugs, no mains plug is supplied with bigger than heater 45

machines. A qualified electrician must install a suitable mains plug. The correct supply

voltage is 380V for Heater 60 Turbo and Heater 80 Turbo. For Heater 45 Turbo, the correct

supply voltage is 220V.

THIS PRODUCT SHOULD BE INSTALLED BY A QUALIFIED

TECHNICIAN,ELECTRICIAN OR ELECTRICAL MAINTENANCE

PERSON FAMILIAR WITH ITS OPERATION AND HAZARDS

INVOLVED!

The wires should be connected as follows:

220V

Phase Black

Neutral Brown

Ground Yellow / Green

380V

T1 (Phase) Black

T2 (Phase) Brown

Ground Yellow / Green

Recommended line protection: 40 A fuse rating for Heater 80 Turbo

16 A fuse rating for Heater 45 Turbo and Heater 60 Turbo

CAUTION!: Verify that the right fuse is installed.

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5- Preparation For Use

• Remove the machine from the box or the bag.

• Locate the machine in the horizontal position on a stable surface.

• Connect the mains plug to outlet.

• For best performance, place the workpiece to turbo's centre to do operation in

Turbo Mode.

• Use the largest yoke so that it completely covers the top of both vertical supports.

• Max Tempereture should be 150 ºC on turbo mode.

Turbo heating Standard heating

• For workpieces, that won't fit over the turbo, follow that step:

• Choose the one of the yokes that fit through the internal diameter of the workpiece

perfectly.

• Be sure, bright underside of the yoke resting evenly on the two vertical supports of

the machine.

• If you will use Temperature Mode, be sure that magnet sensor plugged to the

connector. Place the magnet sensor on the inner ring of the bearing or on the

innermost surface of the workpiece. If you will not connect the temperature probe

to connector, you will see “TEMP SENSOR NOT CONNECTED!” message on the

screen after few seconds then the machine will turn back to main menu.

• If you will use Time Mode, you do not have to connect the magnet sensor to

connector but we highly recommend to connect the temperature probe to check

workpiece's temperature.

• Turn on the main switch. (For Heater 45 Turbo, Heater 60 Turbo)

WARNING! : Heating high conductivity metals like copper, brass and aluminium on

turbo mode may damage the machine!

CAUTION! : If you will operate Heater 60 and Heater 80 continuously with 20x20mm

and 30x30 mm yokes, operate the machine with 220V voltage supply.

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6- Operation

6.1 Control Pannel

1

LCD Screen

2

Power Level Button

3

Temperature Mode Select Button

4

Time Mode Select Button

5

Up

6

Down

7

On/Off

6.2 Power Level selection

You can operate the machine in five different power levels. Pressing button 2 will change

the percentage of the power. During operation, most of the heat will be generated in the

inner side of bearing then the heat will be transferred through the bearing. Because of

that, It is so much important that bearings with small internal clearance or slight preload

are heated slowly. Slow heating avoids possible cause of damage to bearing. There is

many factors that can affect the amount of time required to heat a bearing such as

shape size and internal clearances.

• For sensitive (C1 – C2 clearance) bearings do not exceed 60% power.

• When using the small yoke, never exceed 60% power.

• In the case of overload, the machine will control the current automaticly.

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6.3 Magnet Sensor

• Always use magnet sensor in Temperature Mode. If the sensor got broken or not

connected well, the machine will give “TEMP SENSOR NOT CONNECTED!” error and

generates an acoustic signal after few seconds of operating and it will turn back to

main menu. If sensor doesn't located properly or part's heat is not increasing then

machine will give “PROBE ERROR!!!” and generates an acoustic signal in two

minutes then it will turn back to main menu.

• You can use magnet sensor to check the workpiece's teperature while operating

the machine in Time Mode.

• Magnet sensor's surface always has to be clean.

• Heated workpiece should not touch the magnet sensor's cable.

• Magnetic sensor always has to be attached to inner ring of the bearing. Otherwise,

it may couse damage on the bearing's surface.

• Magnetic sensor always has to be attached to metal surface because of its

magnetic end. Therefore be sure that metal protect attached to magnetic end or

magnet sensor attached to metal surface when you are not using magnetic sensor.

CAUTION!: Do not use magnet sensor, if you will heat the workpiece over 250 ºC.

That will give a damage to magnet sensor. If you want to heat the workpiece over

250 ºC, please use our special production magnet sensor.

CAUTION!: Always attach the magnet sensor to metal surface or attach metal

protector to magnetic end.

6.4 Operating Modes

FeniX induction heaters can be operated in two different heating modes. In main menu

you will see the Temperature Mode and the Time Mode sections. In Temperature Mode,

the machine generates an acoustic signal and returns to main menu, when tempereture

of the workpiece's reaches to set temperature. In Time Mode, on the other hand, the

machine generates an acoustic signal and returns to main menu, when countdown

finishes. In both modes you can select different power levels during operation.

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6.4.1 Temperature Mode

• Press button 3 to operate the machine in Temperature Mode. Set temperature will

be 110 ºC (the default set temperature for bearing is 110 ºC, if you want to work

with higher temperatures please contact with producer of the bearing).

• To change set temperature, press button 5 and button .6

• If you did not choose power level, choose one of the levels according to guidelines

in section 6.2.

• Be sure that Magnet Sensor placed correctly as shown in section 6.3.

• Press button 7 (ON/OFF) to start operation. When the operation start you will see

the screen below. Your set tempereture will appear next to "TARGET TEMP=" and

you will see the workpiece's temperature next to "PART TEMP=" .

• You can change the set temperature during the operation with pressing button 5

or button 6.

• If you want to stop the oparation before reaching set temperature, press button 7.

Demagnetisation will start automaticly.

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• When workpiece's temperature reaches to set temperature, demagnetisation will

start and you will see the screen below and the machine will generates an acoustic

warning signal for few seconds. The machine will be ready to new operation when

demagnetisation process ends.

• Do not forget that, heated workpiece may cause injuries. Use proper handling

equipment to remove workpiece.

• In the case, the magnet sensor not connected or damaged, you will see the

secreen below then it will turn to manin menu. Try to operate the machine after

checking the magnet sensor.

TEMP SENSOR

NOT CONNECTED!

• If damage on magnet sensor can not be fixed, operate the machine in Time Mode.

Do not forget that, heating bearing without checking its tempereture, can give

damage to bearing.

• If the workpiece's temperature will not increase in 2 minutes, or sensor doesn't

located properly the machine will give “Probe Error !!!” message with acoustic

warning signal then will turn to main menu.

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6.4.2 Time Mode

Caution!: When you are operating the machine in Time Mode, be sure that

the workpiece is not overheated. Overheated workpiece may give

damage to the workpiece and/or the machine.

• In the main menu you will have two different heating modes. Press button 4 to

operate the machine in Time Mode.

5.4TIME MODE

• Set the time with pressing button 5 or button 6 .

• If you did not choose power level, choose one of the levels according to guidelines

in section 6.2.

• If you want to check workpiece's temperature, be sure that Magnet Sensor

connected well and placed correctly as shown in section 6.3.

• Press button 5 (ON/OFF) to start operation. When the operation start you will see

the screen below. Your set time will appear next to "TIME LEFT=" and you will see the

workpiece's temperature next to "PART TEMP="

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• If you want to stop the oparation before reaching set temperature, press button 7.

demagnetisation will start automaticly.

• When coundown finishes, demagnetisation will start and you will see the screen

below and the machine will generates an acoustic signal for few seconds. The

machine will be ready to new operation when demagnetisation process ends

7- Overload Warning

FeniX induction heaters designed to change maximum power level automaticly

depending on workpiece's conductivity and size. Power level can be decreased %2 of

total power. If power level is still over the machine design power, the machine will stop

operating and you will recieve screen below.

OVERLOAD

CHANGE PART!

First Switch Off the machine then Switch it On. If you were working in Turbo Mode, try to

work in Normal Mode. If that will not solve your problem, please contact with us for our

other heater models.

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8- Coil Overheated Warning

Operating the machine out of recommended environments and long operation times

with oversized workpiece or bearings may overheat the induction coil. You will recieve

screen below then the machine will stop operating .Wait for 5 minutes until coil cools

down. Be sure operating environment and workpiece is proper as described in user's

manual section 2.2 and section 3.

COIL

OVERHEATED!

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by

Organize Sanayi Bölgesi

8. cad no:5 Balıkesir

Turkey

Tel: +90266 281 12 21

Fax: +90266 281 12 06

www.fenixheaters.com

www.kanallar.com.tr

Due to a policy of continued development, we reserve the right to alter or amend any

published specification without notice. This document may not be copied, reproduced,

transmitted, modified or used, in whole or in part, without the prior written consent of

KANALLAR Ltd.

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