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.

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induction heating Induction Heater JH400
WARNING!
The inductor may be hot. Risk
for burning injuries.
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.
IMPORTANT!
It is the responsibility of the
owner to ensure that the
equipment has been installed
as specied in the instructions
provided. It is also the owner’s
responsibility to ensure that
the equipment is inspected in
accordance with applicable
regulations before it is used.
IMPORTANT!
For the sake of the environ-
ment, it is important that the
equipment is dismantled in an
environmentally friendly way.
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.
WARNING!
Risk for condense in JH400.
Fill the water tank with room
tempered, not cold water. If
moving the JH400 from a cold
place, leave it to rest until
the water warms up to room
temperature.

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induction heating Induction Heater JH400
Undamaged safety signs shall always be
afxed at the indicated places. If any signs are
damaged or missing, the user is responsible
for their immediate replacement. The following
safety signs can be found on the heater:
WARNING
Appropriate protection (protective gloves
and goggles) must be worn when using this
equipment.
WARNING
Sparks from heating could start a re.
WARNING
Risk of tripping on loose hoses, etc.
WARNING
All electrical modications must be made by
a qualied electrician. Disconnect the supply
before performing any service or installation
work.
WARNING
While the Induction heater JH400 is activated
there is a magnetic eld from the inductor
head in the immediate area.
WARNING
The induction heater JH400 can inhibit pulse
generators. A pacemaker may not work
properly in these conditions.
Safety signs

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induction heating Induction Heater JH400
Placement of safety signs
The safety signs are placed at the rear of JH400
as follows:

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induction heating Induction Heater JH400
Safety devices
When the heater is used frequently, the
inductor, the cables, the electronics and
the power transformer become very hot. To
prevent the heater from malfunctioning due to
overheating, it is continuously cooled during
operation. The heater is being permanently
cooled by water running through the inductor.
The water starts owing when the trigger is
activated, and it continues owing about 10
seconds after the trigger has been released. A
sensor detects the water ow and switches off
the heater if the water ow is blocked.
JH400 is connected to earth. There is a
residual current breaker operator (RCBO)
which is built into JH400. There is also a fuse
and if the power exceeds 16 A, the fuse will
switch of the heater.
JH400 also has an over temperature
protection which switches of the heater if it
gets overheated.
The inductor handle is insulated to protect
the user from electrical chocks. The inductor
handle has also a bulge on the end of the
handle to prevent the user’s hand from sliding
down onto the hot inductor.

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induction heating Induction Heater JH400
General
JH400 is inspected and checked prior to
leaving the factory to guarantee consistent
quality and the highest possible reliability.
Instructions for installation, with general tips
and directions, are provided as follows.
INSTALLATION
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.
IMPORTANT!
It is the responsibility of the
owner to ensure that the
equipment has been installed
as specied in the instructions
provided. It is also the owner’s
responsibility to ensure that
the equipment is inspected in
accordance with applicable
regulations before it is used.
Packaging and delivery inspection
Check the delivery against the packing
list, consignment note, or other delivery
documentation to verify that everything is
included and in the correct quantity. Check
JH400 carefully to make sure that no damage
has occurred during transport. If any part is
damaged or missing, the heater may not be
used until the part is repaired or replaced.
If anything is missing, please contact your
supplier. Remove all packaging material from
the heater.

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induction heating Induction Heater JH400
Installation of the wheels
How to lift the JH400
Lift the JH400 in the handle and between the
front and back wheel.

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induction heating Induction Heater JH400
Filling the water tank
Fill the water tank with a mix of decalcied
water and High-tech protection uid
(a JOSAM accessory; mix according to the
instruction on the label).
1. Open the front cover. Loosen the
straps and slide out the water tank.
2. Open the tanks lid and take away the
pump.
3. Fill the water tank.
NOTE: Do not ll up the tank
entirely to allow space for the
hot water to expand. Fill the tank
with 20 litres of uid.
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! Risk for condense
in JH400. Fill the water tank
with room tempered, not cold
water. If moving the JH400 from
a cold place, leave it to rest until
the water warms up to room
temperature.
Water tank
Pump

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induction heating Induction Heater JH400
Connection of electric supply
The heater is designed for 208-240 V, 50-60
Hz. It is tted with a plug that allows it to be
plugged to a wall outlet. The power supply
must have a ground connection, and it must
also be protected with a fuse as follows:
• When using up to step 4 of the output
power, the supply can be protected with a
10 A fuse.
• When using max (step 5) of the output
power, the supply must be protected with a
16 A fuse.
The connection of JH400 to the electrical
supply is done as follows:
• Plug JH400 to a wall outlet.

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induction heating Induction Heater JH400
General
Before you begin using JH400, be sure to read
the instructions in this instruction manual and
that you understand them. JH400 is inspected
and checked prior to leaving the factory to
guarantee consistent quality and maximum
reliability.
JH400 basically consists of an inductor and a
heater unit. A magnetic eld is concentrated
in the inductor when the trigger is activated.
Therefore, the inductor head, the inductor
handle, the cables and the power electronics
are automatically cooled with water as a
cooling agent. The water is kept in the water
tank, which is placed in the heater unit. The
heater unit also contains the control panel and
the holder for the inductor handle.
OPERATION
Control panel Heater unit
On/Off
Water tank
Trigger
Holder for inductor handle
Inductor handle
Inductor head

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induction heating Induction Heater JH400
Key functions
The following key functions are found onto the
control panel:
On/Off
To be able to use the induction heater, the “On/
Off” button must be activated once the heater
as been connected to main supply. Once
this button is activated, one or more of the
yellow LED (light emitting diode) of the power
indicator is lighted up.
Increase power
Increase the power with one step (step 1-5).
Decrease power
Decrease the power with one step (step 1-5).
Power indicator
Indication of selected power (1-5) and that the
unit is switched on.
Power 5
Power 4
Power 3
Power 2
Power 1
Increase power
On/Off Decrease power
Power indicator