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SAFETY PRECAUTIONS – READ BEFORE USING 

 

The symbols shown below are used throughout this 
manual to call attention to and identify possible hazards. 
When you see the symbol, watch out, and follow the 
related instruction to avoid the hazard.  The safety 
information given below is only a summary of the more 
complete safety information found in the Principle Safety 
Standards.    

 

Only qualified persons should install, operate, maintain 
and repair this unit. 

 

During operation, keep everybody, especially children, 
away. 

 

ELECTRIC SHOCK can kill. 

 

Do not touch live electrical parts. 

 

Touching live electrical parts can cause fatal shocks or 
severe burns.  The power circuit and output bus bars or 
connections are electrically live whenever the output is on. 
The input power circuit and machine internal circuits are 
also live when power is on.  Incorrectly installed or 
improperly grounded equipment is a hazard. 

 

Wear dry, hole-free insulating gloves and body protection. 

 

Insulate yourself from work and ground using dry 
insulating mats or covers big enough to prevent any 
physical contact with the work or ground. 

 

Disconnect input power before installing or servicing this 
equipment.  Lockout/tag out input power according to 
OSHA 20 CFR 1910.147 (see Safety Standards). 

 

Properly install and ground this equipment according to its 
Owner’s Manual and national, state, and local codes. 

 

Always verify the supply ground. Check and be sure that 
input power cord ground wire is properly connected to 
ground terminal in disconnect box or that cord plug is 
connected to a properly grounded receptacle outlet. 

 

When making input connections, attach proper grounding 
conductor first – double-check connections. 

 

Frequently inspect input power cord for damage or bare 
wiring-replace cord immediately if damaged.  Bare wiring 
can kill. 

 

Turn off all equipment when not in use. 

 

Do not use worn, damaged, undersized, or spliced cables. 

 

Do not drape cables over your body. 

 

Do not touch power circuit if you are in contact with the 
work, ground, or another power circuit from a different 
machine. 

 

Use only well-maintained equipment.  Repair or replace 
damaged parts at once.  Maintain unit according to 
manual. 

 

Wear a safety harness if working 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. 

INDUCTION HEATING can cause burns. 

 

Hot parts and equipment can injure. 

 

Do not touch hot parts barehanded. 

 

Allow cooling period before handling parts or equipment. 

 

Keep metal jewelry and other metal personal items away 
from head/coil during operation. 

 

Remove all jewelry and other metal objects from body 
before operating this equipment 

 

Persons with metal body implants should not use this 
equipment. 

 

FIRE OR EXPLOSION hazard. 

 

Do not overheat parts and adhesives. 

 

Watch for fire; keep extinguisher nearby. 

 

Do not locate unit on, over, or near combustible surfaces. 

 

Do not install unit near flammables. 

 

Do not operate unit in explosive atmosphere. 

 

Keep aerosol cans and other pressurized containers away 
from induction heating equipment. 

 

FUMES AND GASES can be hazardous. 

 

Keep you head out of the fumes, do not breathe 
the fumes. 

 

If inside, ventilate the area and/or use exhaust to remove 
fumes and gases. 

 

Induction heating of certain materials, adhesives, and 
fluxes can produce fumes and gases.  Breathing these 
fumes and gases can be hazardous to your health. i.e. 
heated urethane releases hydrogen cyanide gas, which 
can be lethal to humans. 

 

If ventilation is poor, use and approved air-supply 
respirator. 

 

Read the Material Safety Data Sheets (MSDS) and the 
manufacturer’s instruction for adhesives, fluxes, metals, 
consumables, coatings, cleaners, and degreasers. 

 

Work in a confined space only if it is well ventilated, or 
while wearing an air-suppliy respirator.  Always have a 
trained watchperson nearby.  Fumes and gases from 
heating can displace air and lower the oxygen level 
causing injury or death.  Be sure the breathing air is safe. 

 

Do not heat in locations near degreasing, cleaning, or 
spraying operations.  The heat can react with vapors to 
form highly toxic and irritating gases. 

 

Do not overheat coated metals, such as galvanized, lead, 
or cadmium plated steel, unless the coating is removed 
from the heated area, the area is well ventilated, and if 
necessary, while wearing an air-supplied respirator.  The 
castings and any metals containing these elements can 
give off toxic fumes if overheated.  See coating MSDS for 
temperature information. 

 
 

Summary of Contents for Car Duction 33

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...

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