JOSAM JH400 User manual

T 98 1 1201
JH400
Instructions for Use and
Safety Regulations
for
Induction Heater
JH400

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induction heating Induction Heater JH400
Foreword 3
Warranty .........................4
Information. . . . . . . . . . . . . . . . . . . . . . . . 5
Marking 7
Name plate .......................7
Safety 8
Warnings and important notices .......8
Safety signs......................12
Placement of safety signs............13
Safety devices ....................14
Installation 15
General .........................15
Packaging and delivery inspection ....15
Installation of the wheels ............16
How to lift the JH400 ...............16
Filling the water tank ...............17
Connection of electric supply. . . . . . . . . 18
Operation 19
General .........................19
Key functions.....................20
Alarm indicators...................21
Over temperature ..............21
Water ow ....................21
General electronic alarm .........21
Operation indicator ................22
Trigger activated ...............22
Using the heater ..................23
Service and maintenance 24
Regular checks ...................24
Every day before use............24
Monthly inspection..............24
Yearly inspection ...............24
Cleaning ........................25
Checking the residual current breaker. . 25
Changing the inductor head
(spare part) ......................26
Changing the eld amplier
(spare part) ......................27
Emptying the water tank ............29
Troubleshooting 30
Troubleshooting table ..............31
General information 32
Manufacturer .....................32
Machine designation ...............32
Intended usage areas and
environments.....................32
Warranty ........................32
Recycling........................32
Service. . . . . . . . . . . . . . . . . . . . . . . . . . 32
Technical data 33
Installation/electric mains connection ..33
Requirements for the ambient
conditions .......................33
CE 34
Conformity with directives and
standards........................34
EC declaration of conformity .........35
TABLE OF CONTENTS

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induction heating Induction Heater JH400
JH400 is a mobile induction heater which is
used to heat metallic parts on vehicles without
damaging nearby parts. All other use of the
equipment, or use that is contrary to the
instructions in this manual, can cause personal
injury and/or machine damage.
JOSAM AB can in no way be held responsible
for intentional or unintentional damage, and
consequent unlimited loss of prot, loss of
income, loss of business opportunity, loss of use
or other similar nuisance, irrespective of how
this has arisen, that originates from incorrect
use of this equipment or its use in a manner not
intended.
FOREWORD

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induction heating Induction Heater JH400
Warranty
JOSAM AB offers a one-year guarantee from
the date of delivery. This guarantee covers
material defects and assumes normal care and
maintenance.
The guarantee assumes that:
• the equipment is correctly installed and
inspected in accordance with current local
regulations.
• the equipment has not been altered or
rebuilt without approval from JOSAM AB.
• genuine JOSAM AB spare parts are used
in any repairs.
• operation and maintenance has been
carried out according to the instructions in
this manual.
All claims on warranty must verify that the fault
has occurred within the guarantee period, plus
that the unit has been used within its operating
range as stated in the specications. All claims
must include the product type and article
number. This data is stamped on the name
plate (refer to section "Marking" for location).

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induction heating Induction Heater JH400
Information
This instruction manual provides advice as
well as instructions for installation, operation,
maintenance and troubleshooting.
The drawings in this manual are intended only to
be illustrative and does not necessarily show the
design of the equipment available on the market
at any given time. The equipment is intended for
use in accordance with current trade practice and
appropriate safety regulations. The equipment
illustrated in the manual may be changed without
prior notice.
The contents in this publication can be changed
without prior notice.
This publication contains information that is
protected by copyright laws. No part of this
publication may be reproduced, stored in a
system for information retrieval or be transmitted
in any form, in any manner, without JOSAM AB’s
written consent.
IMPORTANT! Read this manual
carefully to become familiar
with the proper operation of the
equipment. Do not neglect to do
this as improper handling may
result in personal injury and
damage to the equipment.

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induction heating Induction Heater JH400
JH400 is a mobile induction heater which is
used to heat metallic parts on vehicles without
damaging nearby parts. The induction heater
can produce heat without physical contact and
without an open ame. The heater ensures
minimal dismantling of nearby heat sensitive
parts.
JH400 has a versatile working range. For
example, the heater is used for:
• heating rusted wheel bolts and nuts.
• heating rusted door hinge pins.
• heat shrinking steel and aluminium panels
during repair.
• heating of rusted exhaust manifold ange
bolts in hard to reach places.
• heating of rusted bolts and nuts on the
suspension or steering.
• easy removal of underseal and PVC
coating.
JH400 is principally designed to heat
all magnetic materials (conductors) by
concentrating a powerful magnetic eld at
the head of the inductor. But, the heater also
works well on aluminium. The magnetic eld
alternates at a frequency of approximately
18-40 kHz. The magnetic eld creates eddy
currents in the material, and the electrical
resistance creates heat in the metal.
Since heat is created by electronic losses and
radiation from the work piece, JH400 has an
internal cooling system with water as cooling
agent. The water circuit cools the high power
electronics, cables, inductor handle and
inductor. As soon as the trigger is pressed, the
water pump starts pumping the cooling water in
the heater.
WARNING! All transportation of
JH400 must be done with the
water tank empty or the tank is
placed out side the JH400.
This is due to the risk of water
leakage and possible structural
damage of the chassis of JH400
from living weight of the water.

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induction heating Induction Heater JH400
MARKING
Name plate
The name plate is placed at the rear of JH400.

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induction heating Induction Heater JH400
JH400 has been designed and tested to meet
strict safety requirements. Please read the
following instructions carefully before operating
JH400 and refer to them as needed to ensure
the continued safe operation of the heater.
Information provided in this manual describes
the suggested best working practices and
should in no way take precedence over
individual responsibilities or local regulations.
Great effort has been placed on the design and
manufacture of JH400 so that it will comply
with all applicable safety aspects for this type
of equipment. During operation and other work,
it is always each individual’s responsibility to
consider to their own and other’s personal
safety.
The safety of the heater is assured through the
correct use of the equipment in accordance with
the descriptions and instructions provided in this
manual.
By observing and following the safety
precautions, users of JH400 will ensure safer
working conditions for themselves and their
fellow workers.
Warnings and important notices
The following types of safety signs are used on
the equipment and in JOSAM AB’s instruction
manuals:
SAFETY
PROHIBITED
Prohibits behaviour that can
cause injury.
COMMAND
Prescribes a specic
responsibility or action.

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induction heating Induction Heater JH400
Warning (in bold type) is used in this manual
to indicate a possible danger that could lead
to personal injury. An instruction is normally
given, followed by a short explanation plus
the possible effect if the instruction is not
followed.
The following warnings and important notices
are used in the instruction manual:
Important (in bold type) is used to indicate a
possible danger that could lead to damage to
the equipment and/or cause environmental
damage.
NOTE (in bold type) is used to accentuate
supplementary information that is required
for problem-free use or optimal use of the
equipment. In addition to the safety signs
illustrated in section "Safety signs", the
following warnings and important notices
appear in the manual:
WARNING!
Warns of risks for personal
injuries and or damages to
equipment.

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induction heating Induction Heater JH400
WARNING!
Do not place the induction
heater on an unstable or
uneven ground. The heater
might fall, causing personal
injuries or serious damage to
the heater.
WARNING!
All electrical modications
must be made by a qualied
electrician.
Risk for electrical shock.
WARNING!
Do not ll the water tank with
anything but Decalcied water
mixed with High-Tech uid.
Improper handling may result in
personal injury and/or damage
to the equipment.
WARNING!
Do not touch any object that
has been near the inductor
without ensuring that it has
cooled off.
WARNING!
Do not touch the inductor while
it is activated due to strong
magnetic eld and heat. Risk
for personal injuries.
WARNING!
When using the heater, the
working area should be cleared
from combustible items to
prevent these items from being
ignited.
WARNING!
Make sure that you know
where the re extinguishing
equipment is. Risk for injuries.
WARNING!
If not removing paint or other
chemicals before heating,
use a suction fan to remove
unhealthy fumes. Risk for
personal injury.
WARNING!
When operating, servicing
or working in the immediate
area around JH400, the user
should not wear or use metal
objects such as watches, rings,
keys etc. Otherwise, these
objects could be heated by
the magnetic eld from JH400
which might cause burning
injuries.
WARNING!
Most service must be carried
out by JOSAM AB service
personnel and service support.
Risk for electrical shock.
WARNING!
Never remove any covers
or perform any work to the
induction heater without
unplugging it from the wall
outlet. Wait for ve minutes.
Risk for electrical shock.
WARNING!
Unplug the induction heater
from the wall outlet before
servicing, cleaning or
maintenance.
Risk for electrical shock.
WARNING!
Loose cables and hoses
present tripping risks. Risk of
injuries.