Manual - Induction Innovations
Contents
1. far uhn hahyt Of or relating to a temperature scale that registers the freezing point of water as 32 and the boiling point as 212 at one atmosphere of pressure Farad far uh d tthe SI unit of capacitance formally defined to be the capacitance of a capacitor between the plates of which there appears a potential difference of one volt when it is charged by a quantity of electricity equal to one coulomb Symbol F Fast Off fast awf la registered product name inductor used for removal of body side moldings vinyl graphics and other adhesive bonded parts to automobiles Ferrite fer ahyt chemistry a compound as NaFeO formed when ferric oxide is combined with a more basic metallic oxide Metallurgy the pure iron constituent of ferrous metals as distinguished from the iron carbides Ferrous fer uhs tof or containing iron Flux fluhks The lines of force of an electric or magnetic field Freguencey free kwuhn see tthe number of cycles or completed alternations per unit time of a wave or oscillation Symbol F Abbreviation freq G F L see Ground Fault Interrupter Glass Blaster glahs glas la registered product name inductor used for removal of automotive glass and body panels Can be an attachment or a single attachment hardwired unit Ground Fault Interrupter ground fawlt in tuh ruhp ter ta circuit breaker that senses currents caused by ground faults and rapidly shuts off power before damage can happen to ge2. The Glass Blaster 12 tool shown above is formed in the shape of a shallow upside down U and the magnetic lines of flux pass back and forth in an arc between the pole pieces the two flat square surfaces at the open end points of the U The Glass Blaster tool heats metal at high intensity in the shape of an oval or ellipse centered on the long axis of the tool which makes it ideal for the quick easy and clean removal of automotive glass bonded SMC Panels Bed liner metal bond adhesives etc Tip Practice on a junk car or clip in order to master the techniques of using the Glass Blaster before attempting to work on a customer s car Windshields are laminated glass and very fragile Practice first on the less fragile tempered glass from rear hatches and rear windows The most important thing to remember when using any of the Inductor tools is that it s far better to use too little heat at first and take a few more minutes on the job to gain the experience necessary to use the tool well than to use too much heat and burn the paint ignite the headliner or damage any trim A Removing a Complete Window When the Position of the Urethane Seal is known Step 1 Remove any metallic trim or reveal molding if applicable Step 2 Pull back any non metallic trim or reveal moldings if present Step 3 If you are unfamiliar with the particular model vehicle and where the urethane adhesive seal is relative to the edge of the window glass use y
3. 5 After a few seconds using an I wedge try Panel to lift an edge or portion of the item to be ig removed If it lifts easily keep upward tension on the item and move the Fast Off a bit further on maintaining the circular or reciprocating motion sige If the item does not lift easily apply heat for Molding another a few seconds longer carefully observing any signs of distress in the paint then try lifting the item again Step 6 Repeat these actions until the item 1s entirely removed Step 7 Release the pneumatic foot switch to turn the power OFF NOTE Be careful not to overheat vinyl graphics as they will become too soft to handle and lift up without compromising their integrity and making a mess If they seem to be in this state when you try to lift them release the foot switch to turn the power OFF and let the graphics cool for a minute before trying again to remove them Fast 17 B Removing Body Side Moldings Step 1 Perform the Preparation for Use instructions on pp 12 15 Step 2 Set the power control knob to medium power halfway between the Low and Max settings this is the best setting at which to begin For thicker moldings you can start at a higher power level but until you are experienced start at the halfway level until you determine precisely what power level is best for which type of molding Step 3 Using you I wedge begin to lift molding applying outward pressure on molding Step 4 Step on
4. PAPER MASKS ARE NOT ADEQUATE Wear heat resistant gloves when using the Inductor The Inductor heats metal very quickly You can burn your hands and fingers when trying to remove parts from hot metal surfaces C Electrical Safety Rules A DANGER Do not use the Inductor in the rain moisture or immerse in water Exposing the Inductor to water or other liquids may cause an electrical shock hazard Electrical Safety Rules Continued A _ WARNING A _ WARNING A _ CAUTION _ CAUTION _ CAUTION When operating the Inductor always test the Ground Fault Interrupter GFI to make sure that it is working properly To test the GFI connect the plug to a power source Push the test button on the GFI you will hear a click and the button will pop out from the body of the GFI Step on the pneumatic foot switch it should not beep indicating that the Inductor cannot be turned ON To restore normal operation push the RESET button on the GFI until it clicks and make sure that it remains in the depressed position If the GFI fails the preceding test do NOT use the Inductor Contact Induction Innovations Inc at 877 688 9633 Do not abuse the electrical cords Never use the cords to carry the Inductor or its attachments Keep the cords away from heat oil sharp edges and or moving parts Do not use the Inductor if the cords are damaged Cords cannot be repaired only replaced Dama
5. PRINCIPLES OF OPERATION The GFI 7 and power cord 11 insures a properly grounded 120 VAC power input connection The inverter 1 steps up ordinary 120 volt 60 Hz alternating line current to a high Frequency which the tool Glass Blaster 12 Fast Off 13 Concentrator 14 or Rosebud 15 converts to a high frequency alternating magnetic field This magnetic field crosses the metallic conductive work surface e g the sheet metal of an automobile body panel and vibrates the electrons in the metal through the principle of electromagnetic induction The kinetic energy of the moving electrons is dissipated as heat which warms whatever metal is within the tool s working range about 1 1 2 inches The more easily magnetized a substance is the greater the heat developed in it That is why the Inductor heats ferrous metals and their alloys readily but has no effect on glass plastics wood cloth and other non conductive materials The inverter 1s equipped with a meter 2 which indicates the relative amount of power that is being delivered to the attachment and indirectly the amount of heat created The meter is color coded with green yellow and red ranges indicating respectively low medium and high power generation The meter my also be used to locate hidden metal such as a pinch weld when removing a window The inverter may also have a power control knob 4 to adjust the level of power being delivered to the attac
6. move the Glass Blaster tool closer to the edge of the glass without risking damage to the visible paint Step 10 After the glass has been removed release the foot switch to turn the power OFF and set the Glass Blaster tool down in a secure place Step 11 Turn the power control knob fully counterclockwise to Low if applicable Step 12 Disconnect the plug from the service outlet or extension cord Step 13 Remove the wet towel welding paste or thermal gel and dry any moist areas if further work is to be performed on the vehicle C Removing SMC bonded Roofs and Other Applique s Step 1 Cover the poles of the Glass Blaster tool with a light cloth to avoid scratching the plastic panels Step 2 Follow the steps in Preparation for Use and set the power control knob to the Max Glass Blaster setting Step 3 Apply outward pressure on panel to be removed while placing the glass blaster over the adhered area If adhered area is not known apply 16 pressure and look for slight shallow dimples on panel this is where adhesive remains adhered Step 4 Step on the foot switch to turn the power ON and move the Glass Blaster tool in a back and forth or circular motion over a 4 5 inch radius over the lowest dimple on one side of the panel the glue spots are often several inches in diameter Step 5 Pry gently outward with an I wedge until the adhesive releases the panel Step 6 Be sure to check frequently that the plastic surface does
7. not become too hot Step 7 Use the I wedge to apply constant outward pressure to the panel in the same way that used in glass removal VI USING THE FAST OFF Function The Fast Off 13 is arranged so that the flux lines are spread out evenly over the entire surface of the pad in order to achieve a less intense more evenly distributed heat in the metal to which it is applied While not as strong a heat producer as the Glass Blaster or Concentrator or Rosebud the Fast Off will still burn paint in a very short time if used carelessly The Fast Off is designed for the removal of body side moldings stripes vinyl graphics emblems and other self adhesive trim pieces without damage It can also be flexed to wrap around circular objects i e bearing housing Keep Fast Of A Removing Decals Vinyl Graphics and Striping vat Molding Step 1 Perform the Preparation for Use instructions on pages 12 15 Step 2 Begin with a power setting midway between the Low and Max settings Make adjustments to the power setting after you see how much power the work actually requires Step 3 Step on the pneumatic foot switch to turn the power ON Step 4 Move the Fast Off in a slow circular or back and forth motion over one end of a stripe or linear molding or over a portion of the edge of a decal or graphic Be sure to keep the Fast Off pad parallel to the surface on which the trim item is applied Body Step
8. the Max setting Step 3 Step on the pneumatic foot switch to turn the power ON Step 4 Bring the Concentrator towards the frozen nut keeping a minimum distance of 1 16 inch between the ceramic cloth of the Concentrator and the nut at all times Initially bring the Concentrator close to the nut for only two seconds back it away and try to remove the nut with a wrench or socket If it 1s still frozen apply the Concentrator for another two seconds and then try the wrench again There is usually no 18 CERAMIC CLOTH POLE PIECE jaw reason to heat a nut to a red hot condition in order to free it from the corrosion holding it to the bolt B Removing Caulking Strips 1 Steps 1 through Step 1 Perform the Preparation for Use instructions Step 2 Set the power control knob to halfway between the Low and Max settings Step 3 Step on the foot switch to turn the power ON Step 4 Start by heating one end of the caulking strip for 2 3 seconds and then dig out the caulking with a putty knife or similar tool Slowly work the Concentrator down the length of the strip digging out the hot soft caulking in back of it C Heat Shrinking Hail Soft Dents in Sheet Metal 1 Steps 1 through 4 Side View Step 1 Perform the Crown Hailor SoftDent Crown Preparation for Use instructions Step 2 Set the power TopView oe e control knob to midway Work in a circle between the Low and yeti
9. the pneumatic foot switch to turn the power ON Step 5 Move the Fast Off in a slow back and forth motion over one end of a molding Be sure to keep the Fast Off pad parallel to the surface on which the trim item is applied If the molding lifts easily keep outward tension on the item and move the Fast Off a bit further on maintaining the reciprocating motion If the item does not lift easily apply heat for another few seconds carefully observing any signs of stress in the paint then try lifting the item again Step 6 Repeat these actions until the item 1s entirely removed Step 7 Release the foot switch to turn the power OFF C Warming Cold Body Panels 1 During cold weather the Fast Off pad can be used to warm cold body panels to room temperature so that trim adhesives will stick to them VU USING THE CONCENTRATOR Function The Concentrator 13 is used to heat nuts fasteners hail dent heat shrinking caulking removal frozen door hinges etc The Concentrator must NEVER be used without the heat resistant ceramic cloth shown in the illustration on the facing page because the heat generated in the parts being worked on is sufficient to damage the magnetic ferrite material in the pole pieces A Loosening Corroded Rusted and Frozen Nuts and Bolts Step 1 Perform the ALWATS MAINTAIN AT LEAST A Preparation for Use POLE PIECE jaw rl ME instructions FEES Step 2 Set the power control knob fully clockwise to
10. EN IMPORTANT Read These Operating and Safety Instructions Before Using the Inductor OPERATING AND SAFETY INSTRUCTIONS Specializing in High Performance Induction Heating Systems for the Automotive Aftermarket Induction Innovations Inc Toll Free 877 688 9633 1175 Jansen Farm Court Local 847 836 6933 Elgin IL 60123 Fax 847 551 3369 www theINDUCTOR com Info theinductor com Copyright 2011 Induction Innovations Inc 2 I II IV VE VII VEL IX XI XII XII XIV Table of Contents Page sal RUIS ot EE ye eee ep ele Ve een e e eee KE 3 6 A General Work Area Safety Rules 3 B vE 4 C ElectricalSafetyRules een 4 5 D Fire Hazard Safety Rules sisi 5 6 E Tool Use Safety Rules kai esi dakik ne monde 6 CO NOMS INES pa aka ii ll gel laa eke alamama daki Meis dion 7 10 A InductorR Pro MaxIMComponents 7 B Inductor MaxTMComponents eee 8 C Inductor Attachmentts ccccccsseccessssssvsecorssssssecessesssvsacesseeees 9 D Inductor Glass Blaster Components ssseeeseeeeeeeeeereeerresresereseees 10 Principles OL OPEC At Oikeen nee neue 11 Pie para on Or U Se cmc E E el 11 12 A Generator amp Inverter Use 11 ls EN E 11 2s e e e e eee 11 a ole 6 LO ll O A ke m NS 11 12 Usne the Glass Blaster U esre nea Aion ii de 13 A Removing a Complete Window When the Position of the Urethane Seal 1s
11. HF Male Output Connector Ceramic Heat Cloth 14 HF Male Output A Connector Air Regulator Rosebud Heat Sheild 2 Ne LEE ES HF Male Output Connector 1 Inverter 11 Plug 110 120 AC 2 Power Level Meter 12 Glass Blaster Attachment 3 Serial Plate 13 Fast Off Attachment 4 Power Control Knob 14 Concentrator Attachment 5 Storage case 15 Rosebud Attachment 6 HF Female Output Connector 16 Pneumatic Foot Switch with air hose 7 GFI Ground Fault Interrupter 17 Vent 8 Barb Hose Fitting 18 Instructional DVD Not Shown 9 Handle 19 Owners Manual Not Shown 10 Model 20 I wedge Not Shown 10 C Inductor Glass Blaster Components 1 10 gt g 3 i Serial T diay ciAereh 1 Inverter 2 Power Level Meter 3 Serial Plate 4 Power Control Knob Not with Glass Blaster 5 Storage case 6 HF Female Output Connector Not with Glass Blaster 7 GFI Ground Fault Interrupter 8 Barb Hose Fitting 9 Handle Not Shown sage Tips 17 Es Model Plug 110 120 AC Glass Blaster Attachment Fast Off Attachment Concentrator Attachment Rosebud Attachment Pneumatic Foot Switch with air hose Vent Instructional DVD Not Shown Owners Manual Not Shown wedge Not Shown Refer to the illustrations on this and preceding pages as necessary Numbers in parentheses in the text following refer to callouts on the illustrations 1 HMI IV
12. Max settings Step 3 Step on the foot DME cet switch to turn the power ON Step 4 Holding the Concentrator 2 to 1 inch above a dent move it in a small circular motion and gradually bring it closer to the dent but keeping it around the outside of the crown of the dent As soon as the dent shrinks back the Concentrator away quickly and cool the treated dent with a damp rag If the dent sucks in you are heating the crown or not far enough around the outside of the crown Repeat the procedure until removed completely Tip Once a puff of smoke releases from the dent immediately remove the Concentrator from the area This is the point at which the paint will start to bubble Also be careful on white and light colored finishes these lighter paints tend to yellow sooner than darker colors Trouble Shooting If the dent doesn t seem to want to shrink this may be because there 1s a crease in the metal or the metal has been stretched to far VII Using the Rosebud Function The Rosebud 15 is used for frame rail straightening aluminum annealing de bonding heavy gauged steal etc A Frame Rail Straightening Step 1 Perform the Preparation for Use instructions Step 2 Set the control knob to Max Glass Blaster setting Step 3 Be sure that the Rosebud Heat shield in sitting in place Step 4 Connect the air regulator gauge to a clean dry compressed air source Adjust the air regulator to 15 20 psi Keep the air flow through th
13. R On Line Ir aining program FRAINNCE Induction Heaters www i caronlinetraining com 23 My Inductor Dealer Company Contact Address City State _ Zip Phone Alt Phone Fax Email Website My Inductor Model Pro Max Max Glass Blaster Serial Notes
14. bath towel or similar piece of fabric in water and wring it out so that it is damp but not dripping Roll or fold the towel up the long way and place it on the sheet metal along the length where the glass won t release from the pinch weld Shape the towel to cover the paint next to the length of glass on which you are working The damp towel will act as a heat sink to keep the adjacent painted metal cool A welding paste or thermal gel may be used in place of a damp towel Wet Towel 1 in Pole piece Me VaR Eien uy alana Sy Heal Urethane adhesive oF me Sheet Metal Magnetic flux lines Step 5 With a dry towel wipe up any water that has trickled down the glass Be sure that water is not dripping from the wet towel Step 6 Connect the plug to the service outlet or extension cord Test the GFI by pushing the test button on the plug the reset button on the GFI should pop out and you should hear a click If the GFI fails this test do NOT use the unit Call Induction Innovations Inc at 877 688 9633 for instructions on how to return the unit for repair Step 7 Make sure that the power control knob if applicable is turned clockwise to the maximum position Step 8 Position the Glass Blaster tool on the glass at the problem area Step 9 Step on the foot switch to turn the power ON and continue moving the Glass Blaster tool back and forth at 1 2 inch per second to loosen the glass from the pinch weld With the wet towel in place you can
15. be free from defects in materials and workmanship for one year from the date of first purchase excluding all attachments or hand held tools which are warranted for six months when operated in accordance with the Operating and Safety Instructions Manual Induction Innovations Inc warrants the Inductor Pro Max and any parts thereof to be free from defects in materials and workmanship for two years from the date of first purchase excluding all attachments or hand held tools which are warranted for six months when operated in accordance with the Operating and Safety Instructions Manual This warranty is extended to the original purchaser when proof of purchase is provided Induction Innovations Inc will cover ground transportation costs when returning a unit repaired under warranty This warranty covers only the cost of parts and labor to restore the product to proper operating condition Transportation and incidental costs associated with warranty repairs are not reimbursable under this warranty Warranty service is available only through Induction Innovations Inc This warranty does not cover defects resulting from misuse abuse negligence accidents normal wear alteration modification tampering or repair by anyone other than the manufacture This express warranty is give in lieu of any other warranty either expressed or implied including warranties of merchantability and fitness for a particular use Induction innovations Inc assumes no respon
16. charge of electricity Symbol C Celsius selsios or centigrade Of or relating to a temperature scale that registers the freezing point of water as 0 and the boiling point as 100 under normal atmospheric pressure Circuit sur kit Also called electric circuit the complete path of an electric current including the generating apparatus intervening resistors or capacitors Concentrator kon suh n treyt la registered product name inductor used for removal of hail dents frozen nuts and other frozen or rusted hardware from cars Conductivity kon duhk tiv i tee Also called specific conductance Electricity a measure of the ability of a given substance to conduct electric current equal to the reciprocal of the resistance of the substance Symbol o Current kur uh nt the time rate of flow of electric charge in the direction that a positive moving charge would take and having magnitude equal to the quantity of charge per unit time measured in amperes Degree di gree a unit of measure as of temperature or pressure Eddy Current ed ee kur uhnt an electric current in a conducting material that results from induction by a moving or varying magnetic field Electromagnetic Interference i lek troh mag net ik in ter feer uhns Any electromagnetic disturbance that interrupts obstructs or otherwise degrades or limits the effective performance of electronics electrical equipment abbreviation E M I Fahrenheit
17. e entire use 19 Heat Shield of the Rosebud and for two minutes after use Failure to keep proper air flow may result in unwarrantable damage Step 5 Apply the Rosebud to structural metal component Be sure to follow car manufacture recommended maximum temperature limits using a temperature indicator Failure to do so may result in altering metal properties and reducing or eliminating function of the part B Aluminum Annealing Step 1 Perform the Preparation for Use instructions Step 2 Set the control knob to Max Glass Blaster setting Step 3 Be sure that the Rosebud Heat shield in sitting in place If heat shield is damaged badly and unable to perform its function call Induction Innovations Inc at 877 688 9633 for a replacement shield Step 4 Connect the air regulator gauge to a clean and dry compressed air source Adjust the air regulator to 15 20 psi Keep the air source running through the entire use of the Rosebud and for two minutes after use Failure to keep proper air flow may result in unwarrantable damage Step 5 Apply the Rosebud to Aluminum panel for stress relieving When working with painted surfaces applying a cloth over the heat shield will help prevent from scratching the surface Heating some aluminum alloys above 350 degrees F can degrade the metallurgical properties Consult the metal manufacturer for safe temperature limits and guidelines IX Trouble Shooting 1 The Inductor inverter is designed
18. e you to lose control of the Inductor Work outdoors if there is no danger of rain water or moisture If this is not possible keep the inside work area well ventilated and dry Be sure that ventilation fans are moving air from the inside to the outside Keep a fully charged fire extinguisher at hand at all times when using the Inductor B Personal Safety Rules DANGER iibig Do not operate the Inductor and stay at least twenty feet away from an operating Inductor if you have a cardiac pacemaker or any other kind of electronic or surgical implant The Inductor will interfere with the operation of cardiac pacemakers and other implanted electronic medical devices and can cause dangerous heating of any metal items in your body for example artificial joints and bone screws and braces Do not operate the Inductor while wearing any metallic items such as jewelry rings watches chains identification tags religious medals belt buckles body piercing hardware etc The Inductor can heat these metallic objects very quickly and cause serious burns or even ignite clothing Do not operate the Inductor while under the influence of drugs alcohol or any medication Do not overreach Keep proper footing and balance at all times Proper footing and balance enables better control of the Inductor in unexpected situations Do not use the Inductor within 4 inches of any airbag component The heat created from t
19. ents on the inverter tool power cord connector and then pull the two connector halves apart 20 XI Cleaning Instructions A Proper Cleaning Care Step 1 Use a dry clean non abrasive cloth or paper towels to remove grease oil and other dirt from the tools electrical cords connectors and foot switch before returning them to the storage case Step 2 For grease oil and dirt that is more difficult to remove use generally available nonvolatile automotive interior cleaning products Allow all components to dry completely before using the Inductor amp B Improper Cleaning Care Do NOT immerse any components of the unit in water or a cleaning solution Do NOT spray the unit with a stream of water from a hose or wash any parts under a stream of water from a faucet hydrant or shower Do NOT clean any components with volatile organic compounds such as gasoline benzene kerosene methyl ethyl ketone MEK fuel oil brake part cleaners paint remover and thinners varnish removers plastic adhesive solvents etc These substances are fire hazards and will harden or dissolve the polymer materials used in the Inductor components Do NOT use heat guns space heaters torches microwave or gas ovens etc to dry the components of the Inductor after cleaning XII WARRANTIES AND OR REPAIRS A LIMITED WARRANTY 1 Induction Innovations Inc warrants the Inductor Max and Inductor Glass Blaster and any parts thereof to
20. g for the adhesive Apply pressure to the pneumatic foot switch to turn the power ON again and work back and forth one time over 9 inches at 1 2 inch per second Release the foot switch to turn the power OFF set the Glass Blaster tool aside and gently insert another I wedge to release the urethane adhesive bond Tip Try stacking the I wedges two high if necessary to maintain sufficient outward pressure on the glass Step 9 Continue to work around the remainder of the window in this manner until the entire glass is free After previously released areas have cooled the I wedges are not needed in these locations any longer and they can be removed and reused to the areas where heat is being actively applied to release the urethane adhesive B Stubborn Glass That Won t Release from the Pinch weld Step 1 If you have been following carefully the techniques described in Section A above but a particular piece of glass just won t de adhere from the pinch weld even though you went too close to the edge of the glass and caused a lot of smoke and perhaps came very close to burning the paint this may be due to a narrow pinch weld that is not heating up well or a previous window replacement where the application of adhesive was too heavy 15 Step 2 If the unit is not OFF release the foot switch to turn the power OFF Step 3 Disconnect the plug from the service outlet or extension cord Step 4 Refer to the illustration below Soak a
21. ged cords create electric shock hazards Disconnect the Inductor from the power supply cord before changing any of the applicators Unplug the Inductor from the power supply outlet or cord when not in use Do not use the Inductor if the pneumatic foot switch does not turn the unit ON or OFF EXTENSION CORDS If an extension cord is necessary only the following two cord lengths are authorized for use with the Inductor 25 foot 14 A WG 50 ft 12 A WG Use only one extension cord at any one time Do not connect two or more extension cords in series with each other Do not use any other extension cords except those specified above Unwrap extension cords tightly wrapped extension cords can overheat and cause fires D Fire Hazard Safety Rules Do not attempt to heat aerosol cans paint cans or any pressurized containers used for storing fuels compressed gases and liquids The heat generated by the Inductor can cause these containers to explode and their contents to ignite Fire Hazard Safety Rules Continued pi B nterior trim pieces and headliners may be damaged or ignited by the heat created by the Inductor when removing glass The ignition of these materials may not be readily apparent and could result in property damage and injury to persons When removing windshields and other glass keep the Inductor applicator tool moving in a back and forth motion along with outward pressure Li
22. he Inductor can ignite the air bag propellant causing it to explode without warning Refer to the vehicles service manual for precise airbag location before operating 4 Personal Safety Rules Continued Remove all loose coins metallic tokens keys chains pocket knives miniature tools or any other metallic object in or on your clothing before operating the Inductor Do not replace these items until you are finished using the Inductor The Inductor can heat these metallic objects very quickly and cause serious burns or even ignite clothing Do not wear clothing that is made with metallic pocket rivets waist band buttons pocket buttons and zippers when operating the Inductor The Inductor can heat such metallic items very quickly and cause serious burns or even ignite clothing Do not operate the Inductor while under the influence of drugs alcohol or any medication Always wear safety goggles when using the Inductor Fumes and smoke from hot burning adhesives are toxic Wear a dual filter dust and fume respirator mask which has been approved by the Occupational Safety and Health Administration OSHA the National Institute of Safety and Health NIOSH or the United States Bureau of Mines These masks and replaceable filters are readily available at major hardware stores Be sure the mask fits Beards and facial hair may keep masks from sealing properly Change filters often DISPOSABLE
23. hment Turning the power control knob clockwise increases the power turning it counterclockwise decreases the power The pneumatic foot switch 16 is used to turn the inverter on and off Step or squeeze it to turn on power to the unit The unit will remain ON as long as pressure is applied to the switch Remove pressure from the switch to turn the power OFF Refer to the serial number plate 3 on the inverter and record the serial number on the enclosed Warranty Card for use when making a warranty claim m FOR USE Read and understand all safety warnings and cautions in this manual before operating the Inductor A Generator amp Inverter Use The Inductor is designed to operate from a normal 120 volt alternating current VAC 50 or 60 Hz cycles per second power line or service outlet and will operate without suffering damage on voltages up to 130 VAC 1 Generator Some portable generators particularly low cost units producing 4 kW or less are unregulated and can produce in excess of 140 VAC which will damage the unit and void the warranty If you are in doubt concerning the electrical generator that will be supplying power to the Inductor have a professional electrical contractor measure the generator voltage with a digital voltmeter Measure the voltage with the generator engine warm and no load Some generators the voltage may be reduced by decreasing the engine speed 2 Inverter DC to AC Inverter operation Use only 1 8
24. istance of 9 inches from the corner outward and then back into the corner as shown in the illustration to the right When you reach the corner turn the Glass Blaster tool and move it at the same rate of 1 2 inch per second 9 inches down the other side of the corner and back to the corner Release the foot switch to turn the power OFF WARNING There may be a light trail of smoke from inside the car as the urethane heats up and begins to soften this is quite usual and not a cause for concern If the smoke is heavy black and dense the Glass Blaster tool maybe too close to the edge of the glass and is heating the sheet metal pinch weld too hot This can result in a FIRE HAZARD Step 7 Using the provided I wedge gently pry up on the corner of the glass while simultaneously pushing outward on the glass If the adhesive is reluctant to come free of the pinch weld turn the Inductor ON and place one pole piece of the Glass Blaster tool over the area where you are prying to get a little extra heat When the adhesive bond yields you will hear a popping or ripping sound and see the glass lift a fraction of an inch Release pressure from the pneumatic foot switch to turn the power OFF remove the Glass Blaster tool from the glass and gently insert an I wedge into the gap between the glass and the pinch weld Step 8 Place the Glass Blaster tool back on the glass parallel to an edge at the distance determined by probin
25. kW Prosine 1800 is recommended or larger sine wave inverter The use of square or quasi sine wave inverter will void the warranty Call Induction Innovations Inc at 877 688 9633 before using your Inductor for instructions on how to proceed if you have any questions regarding the instructions furnished above Step 1 Remove the pneumatic foot switch and its attached air line Make sure that the air line is inserted fully on the hose barb fitting on the inverter and that the retaining nut on the fitting 1s tightened 12 Right Way Wrong Way Step 2 Remove the attachment that you intend to use Step 3 Remove the power cord Step 4 Remove the tool cord with its integral female connector Step 5 Make sure that any items stored in the case are not blocking the inverter vents for cooling air Step 6 Make sure that the power control knob is turned fully counterclockwise to Low Step 7 Connect the power plug to a service outlet or extension cord Step 8 Test the GFI 7 for proper functioning by pushing the button labeled TEST the reset button should pop out and you should hear a click A DANGER To reduce the risk of electric shock do not remove modify or immerse the GFI Perform the GFI test every time that you prepare the Inductor for use If the GFI fails this test do NOT use the unit Call Induction Innovations Inc at 877 688 9633 for instructions on how to return the unit for repair Step 8 If the GFI pas
26. known 13 14 B Stubborn Glass That Won t Release from the Pinch Weld 14 15 C Removing SMC bonded RoofsandOtherTrim 15 16 Stee FTO E e EMER e MM Pe A e eee eee 16 17 A Removing Decals Vinyl Graphics andPinStriping 16 B RemovingBodySideMoldings een 17 C Warming Cold Body Panels 17 Use th ONCEMLLALOR aker RES Tr NAN ee ns Matane 17 18 A Loosening Corroded Rusted and Frozen Nuts and Bolts 17 18 B Removing Caulking Strips eee 18 C HeatShrinkingHailDentsinSheetMetal 18 Use eR OSES tics a ans lil ami anla 18 19 A Frame Rail Straightening een 18 19 B Aluminum Anneau nue iais 19 TROWUDICSHOOUING sinen EN 19 Disassembly amp SOLA SS nn tn aaa 19 Clean ne TMS Ui Gii Saanen a a 20 Warranty Go REDAS ne nan ne nn on ne ne see 20 D CORS ee ea re a 21 22 Additonal Trini sere adi aya di io 22 I Safety Rules for Using the Inductor A General Work Area Safety Rules a a i j j m mr mi Read and understand all instructions Failure to follow all instructions listed below may result in electric shock fire and or serious personal injury Keep your work area clean and well illuminated Cluttered and dark areas invite accidents Keep bystanders children visitors and animals away while operating the Inductor These beings may create distractions that caus
27. nerating equipment Henry hen ree the SI unit of inductance formally defined to be the inductance of a closed circuit in which an electromotive force of one volt is produced when the electric current in the circuit varies uniformly at a rate of one ampere per second Abbreviation H Hertz hurts the SI unit of frequency equal to one cycle per second Abbreviation Hz Hysteresis his tuh ree sis tthe delay in response exhibited by a body in reacting to changes in the forces esp magnetic forces affecting it HF High Frequency hi free kwuhn see the range of frequencies in the radio spectrum between 3 and 30 megahertz Inductance in duhk tuh ns that property of a circuit by which a change in current induces by electromagnetic induction an electromotive force Symbol L 22 m Induction in duhk shuh n tthe process by which a body having electric or magnetic properties produces magnetism an electric charge or an electromotive force in a neighboring body without contact Inductor in duhk tor ta coil used to introduce inductance into a ferrous work piece 2 Inductor A registered brand name of the only patented induction heating system for the automotive aftermarket m Inverter in vur ter ta device that converts direct current into alternating current Kilowatt kil uh wot unit of power equal to 1000 watts Abbreviation kW kw Ohm ohm the SI unit of electrical resistance defined to be the elect
28. ngering or pausing in one spot could ignite interior trim and or headliners Do not store miscellaneous items such as rags cloths bags etc in the Inductor storage case Such items may obstruct the cooling air flow to the Power Unit and cause overheating and a fire hazard E Tool Use Safety Rules Bila Do not leave the Inductor unattended when it is ON Make sure that the Power Unit has a sufficient supply of air for cooling Do not operate the Inductor with the top of the storage case closed or partially open Make sure that the vents of the Inductor Power Unit are clean and free of dust and debris so that the Power Unit has an unimpeded flow of cooling air Do not defeat the function of the pneumatic foot switch Do not attempt to repair or service the Inductor There are no user serviceable parts except for renewing the heat barriers on the Concentrator and Rosebud Before plugging in the Inductor make sure that the outlet voltage supplied is compatible with the voltage marked on the nameplate within 10 An outlet voltage incompatible with that specified on the nameplate can result in serious hazards and damage to the Inductor Do not separate the attachment cord connectors from the Inductor cord connector by yanking or pulling on the cords to disengage the connectors If the Inductor is operating when the connectors are separated NON WARRANTABLE damage to the internal electronics of the Ind
29. our I wedge to probe for the location of the urethane adhesive Mark the location of the urethane adhesive refer to illustration above on the glass to assist in placing the Glass Blaster for best performance The ideal placement of the Glass Blaster tool is just inside the edge of the urethane adhesive but never closer than at least one inch from the edge of the glass to avoid burning the good paint Step 4 Turn the power control knob on the inverter all the way clockwise to Full Maximum power also labeled as the Glass Blaster setting but do NOT turn ON the Inductor yet Tip The best place to start on most glass is at a corner Pick a corner that is accessible from the inside and the outside of the vehicle so that 14 you can apply outward pressure on the glass to break the urethane bond after heat has been applied to the pinch weld by the Glass Blaster tool Step 5 Position the Glass Blaster tool on the glass near a corner with the two flat pole piece surfaces on the glass and with its long axis aligned with the inside edge of the urethane adhesive that you have measured already Use a marking tool to make some guide lines if they will help you keep the Glass Blaster tool at the inside edge of the urethane adhesive Step 6 Step on the foot switch to turn the power ON Immediately begin to move the Glass Blaster tool parallel to the horizontal or vertical side of the corner at a rate of 1 2 inch per second for a d
30. rical resistance between two points of a conductor when a constant potential difference applied between these points produces in this conductor a current of one ampere The resistance in ohms is numerically equal to the magnitude of the potential difference Symbol Resistance ri zis tuh ns la property of a conductor by virtue of which the passage of current is opposed causing electric energy to be transformed into heat Rosebud rohz buhd la registered product name inductor used for annealing warming of frame rail for straightening etc Temper tem per the degree of hardness and strength imparted to a metal as by quenching heat treatment or cold working the operation of tempering Volt vohit the SI unit of potential difference and electromotive force formally defined to be the difference of electric potential between two points of a conductor carrying a constant current of one ampere when the power dissipated between these points is equal to one watt Abbreviation V m Voltage vohl tij electromotive force or potential difference expressed in volts Watt wot the SI unit of power equivalent to one joule per second and equal to the power in a circuit in which a current of one ampere flows across a potential difference of one volt Abbreviation W w XIV Additional Training A Additional Training is available online through I CAR 1 Induction Heaters INHO1 TRAINING As seen in the I CA
31. ses its test connect the tool to the tool power cord and connector See diagram below Align the brass straps on each of the multi contact connectors and press them together gently until the two latches engage fully with a click Brass Strap Step 9 Hold the applicator head of the tool away from metallic objects Step 10 Step on the foot switch to see if the inverter will turn ON If it does you will hear a continuous beeping sound from the inverter Release the foot switch to turn the power OFF while you position yourself and the tool for work If the inverter will not turn ON and OFF when the foot switch is pressed and released do NOT use the unit Call the Technical Services Department of Induction Innovations Inc at 877 688 9633 for instructions on how to return the unit for repair 14 If you have observed all the Safety Rules of this manual you are now ready to begin using the Inductor If you have not read and followed all the Safety Rules DO SO NOW before using the unit If there is anything in these Instructions that you do not understand completely DO NOT ATTEMPT TO USE the Inductor Call Induction Innovations Inc at 877 688 9633 for instructions on how to proceed 13 V USING THE GLASS BLASTER Kaan tool GLASS 7 ep tom BLASTER Probe 1 inch from edge of paint Pole pece i il GLASS i yi Urethane adhesive Lee E tn ia a Probe Sheet Magnetic Metal Flux Lines Functions
32. sibility for indirect incidental or consequential damages Some states do not allow the exclusion or limitations of incidental or consequential damages or limitations or exclusions may not apply to you This Limited Warranty gives you specific legal rights and you may also have other rights which vary from state to state Warranty is not valid unless the warranty card is returned within 30 days of the date of purchase No unit will be warranted without proof of purchase Shipping will be at the consumer s own expense Return shipping will be at the factory s expense for units repaired under warranty Return shipping will be via ground unless the consumer wishes to pay for faster service Induction Innovations Incorporated is not responsible for lost stolen or damaged unit s due to shipping Warranty is non transferable When returning an Inductor all attachments and accessories must be returned with the unit to qualify it for warranty repair Call 877 688 9633 for return authorization prior to shipment Warranty amp Repair Service Induction Innovations Inc 1175 Jansen Farm Court Elgin IL 60123 21 XMI De finitions Anneal uh neel tto heat metals to remove or prevent internal stress Ampere am peer am peer tthe base SI unit of electrical current equivalent to one coulomb per second Abbreviation A amp AWG labbreviation for American Wire Gauge Capacitance kuh pas i tuhns the property of being able to collect a
33. to stop running if overheated If the unit stops suddenly check for proper GFI operation and insure unit is still plugged into a functioning AC power outlet Also be sure if using an extension cord that there are no cuts in the cord Allow the unit to cool off for at least 30 minuets and then restart If problems persist call Induction Innovations Inc at 877 688 9633 2 If there is a lack of power output this may be from using an improper extension cord or a damaged attachment The proper gauge and length cord is 25 ft 14 AWG or 50 ft 12 AWG Do not use more than one extension cord at once 3 For other problems contact Induction Innovations Inc at 877 688 9633 X Disassembly and Storage Step 1 When you are finished working turn the power OFF by releasing the foot switch and make sure that the beeping stops If the Inductore will not turn OFF by releasing the pressure on the foot switch set the tool down in a place where it will not heat anything metallic and disconnect the plug from the service outlet or extension cord Call Induction Innovations Inc at 877 688 9633 for instructions on how to return the unit for repair Step 2 Disconnect the plug 11 from the service outlet or extension cord Step 3 If applicable disconnect the tool from the HF female output connector 6 Separate the halves of the connector by squeezing and holding open the plastic latches of the connector on the tool electrical cord to disengage them from the det
34. uctor may occur Do not twist or bend electrical cords sharply or damage to internal wiring will result Il Components A Inductor Pro Max Components Serial impor nl Read all psralar ard Sea y re heloru underside Inverter Power Level Meter Serial Plate Power Control Knob Storage case HF Female Output Connector GFI Ground Fault Interrupter Barb Hose Fitting Handle 0 Model INDUCTOR PRO MAX pil 220 w DAS LWAH 25973 WY SYSTEM FLAMELESS HE T Guru DO w Plug 110 120 AC Glass Blaster Attachment Fast Off Attachment Concentrator Attachment Rosebud Attachment Pneumatic Foot Switch with air hose Vent Instructional DVD Not Shown Owners Manual Not Shown wedge Not Shown 17 Ge 0 B Inductor Max Components 5 g 10 IM DU TS F es ilin Max 2 Inverter 11 Plug 110 120 AC Power Level Meter 12 Glass Blaster Attachment Serial Plate 13 Fast Off Attachment Power Control Knob 14 Concentrator Attachment Storage case 15 Rosebud Attachment HF Female Output Connector 16 Pneumatic Foot Switch with air hose GFI Ground Fault Interrupter 17 Vent Barb Hose Fitting 18 Instructional DVD Not Shown Handle Not Shown 19 Owners Manual Not Shown 0 Model 20 I wedge Not Shown T i F a KR 1 a a z pi o Inductor Attachments 12 m D HF Male Output Connector 13
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