GYS Car Duction 33, Owner'S/Operator'S Manual

Page 1: ...Car Duction 33 Induction Heating System Owner Operator s Manual GYS S A S Tel 33 0 2 43 01 23 60 www gys fr email contact gys fr ...

Page 2: ... Introduction and Warranty 3 Specifications 4 Connections and Utilization 5 Usage of the Body Pro Inductor 9 Usage of the Bolt Pro Inductor 10 Usage of the Glass Pro Inductgor 11 Usage of the Magnepopper Inductor 15 Routine Maintenance 17 Spare Parts 18 Product Registration 21 ...

Page 3: ...g above floor level Keep all panels and covers securely in place SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters Turn Off inverter disconnect input power Wait 5 minutes before removing top cover to allow time for AC and DC capacitors to discharge INDUCTIONHEATINGcan causeburns Hot parts and equipment can injure Do not touch hot parts barehanded Allow cooling period before h...

Page 4: ...tion regularly checked and maintained Keep high frequency source doors and panels tightly shut Do not use the CarDuction Induction System near driver or passenger air bags The heat produced by the CarDuction can ignite the airbag propellant causing the bag to inflate without warning Refer to vehicle manufacturer s service manual for exact location of all airbags before working on a vehicle Be awar...

Page 5: ...attachments do not get hot or produce any heat Only an invisible magnetic field is emitted from the inductor heads WARRANTY Ajax Tocco offers a 1 year guarantee from the date of the delivery for the power supply This guarantee covers material defects and assumes normal care and maintenance Heating inductors are not covered by warranty and are considered consumable items Inductors are guaranteed to...

Page 6: ...ply only attachments and peripherals increase weight Input rated output Input Voltage 120 240 Vac 50 60 Hz 1 phase Input Current 15 amps Output maximum values to induction coil Power 1500 3000 Watts Voltage 400 Vrms 45 60kHz 1 phase Current 60 amps 14 P F minimum Cooling Forced air cooling via internal cooling fans Operating Temperature 125F 52C Max ...

Page 7: ... the system has to be shipped back to our factory for future service Ajax Tocco Magnethermic will not guarantee safety of the system if shipped in non Ajax Tocco Magnethermic approved packaging CONNECTION OF ELECTRIC SUPPLY The heater is designed for 120 or 240 Vac Single Phase 50 60 Hz input It is fitted with an IEC C 20 input receptacle on the rear that allows different cord configurations to be...

Page 8: ...olding the jumper in place Do not completely remove the bolts Loosen the adjacent bolt to the right or left of the jumper depending on which voltage configuration it is currently in Slide the jumper from beneath the bolts and re install the jumper in the alternate position The center bolt standoff is always connected to the jumper Tighten all bolts after re locating the jumper A schematic illustra...

Page 9: ...heating inductor that is suspect of an unsafe condition 2 Connect one of the supplied heating inductors 7 to the induction power source by inserting the plug into the HF receptacle 8 located on the front of the induction power source The inductors are keyed and will only connect in one direction One side of the inductor plug has a hole in it see illustration on next page which marks the top of the...

Page 10: ...he inverter power supply A schematic detailing the proper location of the jumper is located just in front of the jumper inside the cabinet 5 Close circuit breaker CB1 5 The circuit breaker should remain closed in the on position If it doesn t stop use immediately and contact customer service for additional instructions The internal cooling fans should be operating at this point 6 Select the desire...

Page 11: ...ll the glue should be removed with the stripe Body side molding removal Body side moldings are removed in much the same way as decals and graphics However with thick moldings a higher power or time is needed since the metal underneath the molding is farther away from the pad Keep the pad parallel to the work surface for even heat distribution Also instead of a circular motion use a back and forth ...

Page 12: ...ctor and the part being heated A small piece of welding blanket or fiberglass cloth can be placed over the jaws of the Bolt Pro Inductor to help shield it from the radiated heat from the fastener as well as protect it from accidental contact with a hot part If the Bolt Pro inductor is in contact with the hot part it could cause un warranted damage The maximum temperature allowed for he inductor is...

Page 13: ...ting point of the glass removal due to the difficulty of getting the first wedge in place It s best to start in a corner if possible and progress around the window towards the undamaged area of the vehicle 8 Ideally the Glass Pro Inductor should be placed directly on top of the urethane for efficient window removal However some vehicles have narrow pinch welds that cause the Glass Pro Inductor to ...

Page 14: ... with rear or side glass first then progress to windshields as you gain experience It s best to practice on salvage or totaled vehicles first to get familiar with the techniques 13 Add wedges or reposition other wedges as you move around the glass Tempered glass can withstand some prying without breaking If a prying action is used it is best to pry away from the car to prevent unnecessary paint da...

Page 15: ...GlassProInductor 13 Glass Removal Illustration NOTES ...

Page 16: ...GlassProInductor 14 ...

Page 17: ...e dent to expand upward thus removing the dent In some cases the dent will increase in size when heated If this occurs move out to the outer edge of the dent and heat again Continue to move outward until the dent starts to decrease in size Large dents and swells required a circular motion starting at the perimeter of the dent progressing to the middle It is possible and recommended to over raise t...

Page 18: ...ng bearings for thermal expansion prior to installation NOTE Never apply power to an unloaded heating inductor The body panel or metal object to be heated acts as a load to absorb the energy generated by the inductor Without the load the inductor will overheat Overheating the inductor can cause damage and or personal injury ...

Page 19: ...ooling fans and very adequate air flow from the louvers located on the side of the power source Frequently inspect all input power cables as well as all inductor and foot switch cables for signs of wear Do this daily Replace or repair cables as needed Disconnect input power and tighten all internal electrical connections every 6 months Heating and cooling of the electrical components from normal u...