JOSAM JH1500 User manual

T 152 1 130915236
Instructions for use and
safety regulations
for
Induction heater
JH1500

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induction heating Induction heater JH1500
Information
This instruction book provides advice
and directions for installation, handling,
maintenance and troubleshooting.
IMPORTANT! Read this instruction book
carefully so you can learn the correct way of
using the induction heater. Do not neglect to
do this, since incorrect handling can lead to
personal injury and damage to the equipment.
The illustrations in the instruction book are
only to help with comprehension and do not
necessarily represent the equipment's exact
appearance. The equipment is intended to
be used in accordance with current practice
and the applicable safety regulations.The
equipment, as shown in the instruction
book, may be changed in the future without
warning.
The content of this instruction book can also
be changed without warning.
This instruction book contains information
that is protected by the Copyright Act. No
part of this publication may be reproduced
or published without the written consent of
JOSAM AB.
Conformance with directives and
standards
The JH1500 series is designed and
manufactured by JOSAM AB, an
EN‑ISO9001/14001 certied development
and manufacturing company. The JH1500
series conforms with the requirements in the
CE standard.
PREFACE
JH1500 is a mobile induction heater, which
is used for heating metal parts on vehicles
without damaging nearby parts. All other use
of the equipment or use that does not comply
with the instructions in this instruction book,
can cause personal injury and/or damage to
the machine.
If the equipment is used incorrectly, JOSAM
AB cannot be held liable for damage to
the equipment, irrespective of whether the
damage has been caused intentionally or
unintentionally. Nor will JOSAM AB accept
liability for any subsequent nancial losses or
loss of income.
Warranty
JOSAM AB provides a one year warranty
from the machine's delivery date and a
three months warranty on consumable parts
(inductor). The warranty covers material faults
and presupposes normal care and normal
maintenance.
The warranty presupposes that:
• the equipment is installed correctly
and inspected in accordance with the
applicable regulations,
• the equipment has not been modied or
rebuilt without the consent of JOSAM AB,
• only original spare parts from JOSAM AB
have been used in the event of any repairs,
• handling and maintenance has been
performed according to the directions in
this instruction book.
In the event of any complaint, verication is
required that the fault has occurred during the
warranty period and that the equipment has
been used within the capacity limits stated
in the technical data. In the event of any
complaint, the product type and article number
must be stated. These details can be found on
the identication plate, see chapter "Marking".

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induction heating Induction heater JH1500
CE CERTIFICATE

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induction heating Induction heater JH1500
TABLE OF CONTENTS
Preface 2
Warranty .........................2
Information........................2
Conformance with directives
and standards .....................2
CE certicate 3
Table of contents 4
Introduction 5
General Information.................5
Marking .......................6
Safety 7
General information.................7
General warnings ..................8
Safety sign.......................10
The placing of the safety sign ........11
Safety devices ....................11
Installation 12
Packaging check and delivery ........12
Filling the water tank ...............13
Connection to the electric supply......14
Description 15
Cooler section ....................16
Electrical section ..................17
Main power switch ..............18
Residual current breaker .........18
Main fuse.....................18
Cooler fuse ...................18
USB connection................18
Control panel .....................19
Alarm indicators................20
Operation indicator .............20
Hose packet......................21
Connection block ...............21
Handheld transformer with hose kit . 21
Trigger button..................21
Inductor ......................22
Usage 23
General information about induction ...23
Information about heating ...........23
Heating .........................24
After completed work...............25
Maintenance instructions 26
Maintenance interval ...............26
Maintenance description ............26
Check the cooling water .........26
Check the residual current breaker . 26
Check the hose couplings ........27
Check and clean the condenser ...27
Check cable glands on the
connection block ...............27
Fitting the inductor ..............27
Troubleshooting 28
Troubleshooting table...............29
General information 31
Manufacturer .....................31
Machine designation ...............31
Intended usage areas
and environments .................31
Warranty ........................31
Recycling ........................31
Service .........................31
Technical data 32

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induction heating Induction heater JH1500
General information
JH1500 is a mobile induction heater, which is
used for heating up metal parts on vehicles
without damaging nearby parts. The induction
heater produces heat without physical contact
and without naked ames. Using the induction
heater makes it possible to leave nearby,
sensitive parts in place.
The are many application areas for the JH1500.
For example, the induction heater can be used
for:
• Heating nuts and bolts that have rusted in
place
• Heating hinge pins that have rusted in place
• Heat‑shrinking steel and aluminium panels
when making repairs
• Heating, for example, couplings to exhaust
systems that have rusted in place and
places that are difficult to reach
• Heating screws that have rusted in place
• Nuts on the suspension or the steering
• Simple removal of underbody protection and
PVC coating
• Frame straightening
The JH1500 is designed to heat metals, by
concentrating a powerful magnetic eld at the
inductor head.The induction heater also works
well on aluminium. The magnetic eld alternates
at a frequency of ca 14‑30kHz. The magnetic
eld induces eddy currents in the material, and
the electrical resistance produces heat in the
metal.
Since heat is created due to electrical losses
and radiation from the plates, JH1500 has an
internal cooling system, using water as the
coolant. The water circuit cools the high‑power
electronics, cables, induction handle and
inductor. When the machine starts, the water
pump begins to pump the cooling water in the
induction heater.
INTRODUCTION

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induction heating Induction heater JH1500
Marking
The identication plate is located on the back
of the JH1500.
##### #####
400 V 200 V

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induction heating Induction heater JH1500
General information
The JH1500 is designed and tested to conform
to the strictest safety requirements. Read the
following instructions carefully before you start
using the JH1500 and pay attention to the
applicable operating instructions, in order to
operate the induction heater safely.
The information provided in this manual
describes the work routines that we consider
work best, but may under no circumstances
be used as an excuse to ignore one's
own personal responsibility or applicable
regulations.
Great care has been taken during the design
and manufacture of the JH1500 to ensure
the system conforms with the applicable
safety regulations for this type of equipment.
During use and other work, everyone has a
personal responsibility for their own and other
individuals' safety.
Safe use of the induction heater is
guaranteed by using the equipment correctly,
in accordance with the descriptions and
instructions in this manual. By reading and
following the safety regulations, the JH1500
user can ensure a safe work environment for
himself/herself and his/her colleagues.
SAFETY

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induction heating Induction heater JH1500
WARNING!
Do not ll the water tank with
anything other than decalcied
water mixed with propylene
glycol. Incorrect handling can
cause personal injury and/or
damage to equipment.
WARNING!
Warning is used in this manual
to draw attention to possible
dangers that can result in
personal injury. When an
instruction is given, it is normally
followed by a short explanation
and the possible results if the
instruction is not followed.
NOTE!
Note is used to indicate
additional information that
should be followed to obtain
problem free or the best use of
the equipment.
IMPORTANT!
Important is used to draw
attention to possible dangers
that can result in damage
to the equipment and/or the
environment.
The following types of warnings and
information are used in this manual:
Apart from the safety signs shown in
the section "Safety Signs", the following
warnings and important information can
be found in the operating instructions:
WARNING! Do not place the
induction heater on unlevel or
instable surfaces. The induction
heater can fall over and cause
personal injury or serious
damage to the induction heater.
WARNING! All electrical modi‑
cations must be performed by
a qualied electrician.
Danger of electrical shocks.
WARNING! Do not touch
objects that have been close to
the inductor without checking
that they have cooled down.
WARNING! Do not touch the
inductor while it is activated
and the strong magnetic eld
and the heat are on. Danger of
personal injury.
WARNING! The work area
must be kept free of ammable
material when you are working
with the induction heater.
WARNING! Make sure that re
ghting equipment is available.
Danger of personal injury.
WARNING! Loose cables
and hoses constitute a risk for
tripping. Danger of personal
injury.
WARNING! If you do not remove
paint and other chemicals from
the material before you heat it
up, you must use an extraction
fan to remove vapours that are
injurious to health. Danger of
personal injury.
GENERAL WARNINGS

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induction heating Induction heater JH1500
WARNING! It is the owner's
responsibility to ensure that the
equipment has been installed in
accordance with the instructions
in this manual. It is also the
owner's responsibility to ensure
that the equipment is inspected
according to the applicable
regulations before it is used.
IMPORTANT! Risk of con‑
densation in the JH1500. Fill the
water tank with room tempered,
not cold, water. If you move the
JH1500 from a cold location,
you should wait until the
water has warmed up to room
temperature before use.
IMPORTANT!
During transport the water
tank must always be sealed.
Otherwise, there is a risk of
water leaks.
WARNING! When you are
using the JH1500, performing
maintenance on it or working
near it, do not wear or use metal
objects such as watches, rings,
keys, etc. The objects can be
heated up by the magnetic eld
from the JH1500 and cause
burn injuries.
WARNING! Most of the
servicing must be performed
by service personnel or service
support from JOSAM AB.
Danger of electrical shocks.
WARNING! Never remove any
of the protective covers and
never perform any work on the
induction heater without rst
pulling the plug out of the wall
socket. Wait one minute. Danger
of electrical shocks.
WARNING! Remove the
induction heater's plug from the
wall socket before you begin
any form of service, cleaning
or maintenance. Danger of
electrical shocks.
WARNING! The inductor can
become very hot. Danger of
burn injuries.
WARNING! Read this manual
carefully so you can learn how
the equipment is to be used in
the right way. Do not neglect to
do this, since incorrect handling
can lead to personal injury and
damage to the equipment.
IMPORTANT! For
environmental reasons, it is
important that the equipment
is disassembled in an
environmentally friendly way.
GENERAL WARNINGS

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induction heating Induction heater JH1500
Safety sign
The safety sign must always be present and in
good condition, attached to the stated place.
If the sign is damaged or is missing, the owner
bears the responsibility for replacing it without
delay.
You can nd the following safety symbols on
the induction heater:
WARNING
Wear suitable safety equipment (protective
gloves and safety goggles) when you use the
equipment.
WARNING
Sparks from the induction heater can cause
res.
WARNING
Danger of tripping over loose hoses etc.
WARNING
Always read the user instructions before using
the product.
WARNING
Residual voltage. Wait one minute after
disconnecting before opening enclosure.
WARNING
When the JH1500 induction heater is activated,
there is a magnetic eld from the induction
head in its immediate vicinity.
WARNING
The JH1500 induction heater can interfere
with pulse generators. It is possible that a
pacemaker will not function correctly in the
vicinity.

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induction heating Induction heater JH1500
The placing of the safety sign
The safety sign is placed on the back of the
JH1500, as in the picture.
Safety devices
When the induction heater is in use, the
inductor, cables, electronics and transformer
can frequently become very hot. To protect
the induction heater from overheating, it is
cooled continuously when in operation. The
induction heater is cooled all the time by
water that circulates through the inductor. The
water begins to circulate when the machine is
started. A sensor detects the water ow and
trips the induction heater if the ow is blocked.
The JH1500 must be connected to earth.
It has an inbuilt residual current breaker to
protect the user in case of a ground fault. It
also has an automatic fuse, which trips if the
current exceeds 32 A (for JH1500‑400V) or
63A(forJH1500‑200V).
In case the JH15000 would get overheated,
the overheating protection automatically
disables the heating function to protect the
machine and its electronic parts. However, the
cooling system continues to cool the machine
to make it ready for operation again.
The inductor handle is insulated to protect the
user from electric shocks.

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induction heating Induction heater JH1500
The JH1500 is inspected and tested before it
leaves the factory to warrant uniform quality
and the greatest possible reliability. Below
follows a description of the installation and
general tips and instructions.
INSTALLATION
WARNING! Do not place the
induction heater on uneven or
unstable surfaces. The induction
heater can fall over and cause
personal injury or serious damage
to the induction heater.
WARNING! It is the owner's
responsibility to ensure that the
equipment has been installed in
accordance with the instructions
in this instruction book. It is
also the owner's responsibility
to ensure that the equipment is
inspected according to applicable
regulations before it is used.
Packaging check and delivery
Check the delivery against the packing
list, consignment note or other delivery
documentation to ensure that everything is
included in the correct quantities. Check the
JH1500 carefully, to assure yourself that no
damage has been incurred during transport.
If any part has been damaged or is missing,
the induction heater must not be used before
the part has been repaired or replaced. If
there is anything missing, contact the supplier.
Remove all of the packaging material from the
induction heater.

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induction heating Induction heater JH1500
Filling the water tank
The JH1500 is delivered with a lled water
tank, but if the tank needs to be lled manually
at some point, follow the instructions below.
Fill the water tank with a mixture of decalcied
water and 30 % propylene glycol.
1. Open the front cover.
2. Open the tank cap.
3. Fill the water tank (it should be lled to
between 80‑90%).
WARNING! Do not ll the
water tank with anything other
than decalcied water mixed
with propylene glycol. Incorrect
handling can cause personal
harm and/or damage to
equipment.
NOTE! Do not ll the tank
completely, since the water
expands as it heats up. Fill the
tank with 35 litres of uid.
IMPORTANT! Risk of
condensation in the JH1500.
Fill the water tank with room
tempered, not cold, water. If you
move the JH1500 from a cold
location, you should wait until
the water has warmed up to
room temperature before use.
INSTALLATION

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induction heating Induction heater JH1500
Connection to the electric supply
The induction heater is available in two
versions: 200 V or 400 V, 50–60Hz. The 400V
version is equipped with a plug so it can be
plugged into a wall socket. The source of
electrical current must be earthed and it must
also be protected by a fuse, according to the
following:
• The electric supply must be protected by
a 32A(400V) or 63A(200V) fuse when
using maximum power (step 5).
The JH1500 is connected to the electric mains
as follows:
• Plug the JH1500 into a wall socket.
INSTALLATION
NOTE! The JH1500‑200 V is
delivered without a plug.
A plug suited for local electrical
conditions must be acquired
separately and mounted by a
qualied electrician.

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induction heating Induction heater JH1500
The machine comprises:
1. cooler section
2. electrical section
3. hose packet with inductor
During heating, a powerful magnetic eld is
concentrated in the inductor. The magnetic eld
alternates direction and induces eddy currents
in the material, which gives rise to heat. Since
intense heat is created in the work piece and
inductor, cooling water is used for cooling the
machine and its electronic parts. The control of
the cooling system is totally automatic.
The connection cable provides the machine's
electrical section with current, which in turn
power supplies the hose packet, inductor and
cooler section. The cooling section controls the
temperature of the components by circulating
cooling water in the hose packet, inductor and
a cooling block in the electrical section.
DESCRIPTION
1
2
3

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induction heating Induction heater JH1500
Cooler section
The cooler section consists of a:
1. cooling water tank
2. water pump
3. connection box
4. condenser
5. condenser fan
DESCRIPTION
1
2
5
3
5
4

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induction heating Induction heater JH1500
Electrical section
The electrical section has three main functions,
namely supplying current to: the hose packet,
electronic components and the cooling section.
The electrical section comprises:
1. control panel
2. main power switch
3. residual current breaker
4. main fuse (32 A/400 V or 63 A/200 V)
5. cooler fuse (10 A/400 V or 16 A/200 V)
6. USB connection
2
345
6
DESCRIPTION
1

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induction heating Induction heater JH1500
Main power switch
When the main power switch is turned on, the
machine is connected to the electrical supply.
Residual current breaker
The machine is equipped with a residual
current breaker, which trips in the event of
an earth fault. There is a test button on the
residual current breaker. When the test button
is pressed, the residual current breaker should
trip.
Main fuse (32 A/400 V or 63 A/200 V)
The main fuse trips in the event of a fault in the
current supply to the hose packet.
Cooler fuse (10 A/400 V or 16 A/200 V)
The cooler fuse trips in the event of a fault in
the current supply to the water pump, fan or
compressor.
USB connection
For service work and updates.
DESCRIPTION

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induction heating Induction heater JH1500
Control panel
Increase power
Reduce power
Power indicator
On/Off
Operation indicatorAlarm indicators
DESCRIPTION
The following functions can be found on the
control panel.
On/Off
To use the induction heater, after it has been
connected to the electric mains, you must press
the On/Off button. When you have pressed the
button, one or more of the yellow LEDs lights up
on the power indicator.
Increase power
Increase power by one step (step 1‑5).
Reduce power
Decrease power by one step (step 1‑5).
Power indicator
Shows the chosen power (1‑5) and that the
unit is on.
Power 5
Power 4
Power 3
Power 2
Power 1

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induction heating Induction heater JH1500
Alarm indicators
The alarm indicators notify the user if a fault
occurs with the induction heater.
The alarm indicators are marked by a red LED.
Overheating
The red LED for overheating lights, if the
electronics become overheated. The induction
heater does not function if this indicator is
lit. The light goes out, when the temperature
drops below the warning limit.
Water ow
The red LED for the water ow lights, if the
cooling water is not owing as it should, that is,
if the water pressure is too low. The induction
heater does not function when this indicator is
lit.
General electronic alarm
If both LEDs are blinking at the same time,
the cause is often that one of the phases is
missing in the wall outlet. This alarm indication
will also be shown if the machine is consuming
current even though it is in idle, or if a current
sensor is faulty.
Operation indicator / Trigger activated
The operation indicator provides the user with
information when the induction heater is in use.
The green LED begins to blink when the
trigger is pressed in. It indicates that the cable
to the handheld transformer isn't damaged,
that the water ow is functioning and that
correct power is reached in the inductor head.
DESCRIPTION