Mini-Ductor II Instruction Manual
Contents
1. ga 5 _ ah pm J ININ F k II IV V PRINCIPLES OF OPERATION The power cord when connected to a GFI outlet 11 insures a properly grounded 230 VAC power input connection The inverter 1 steps up ordinary 230 volt 50 Hz alternating line current A work coil the Bearing Buddy Coil 8 U Form Coil 9 Preformed Coil 7 or Mini Pad 10 is inserted into the end of the electrodes 13 and then secured into place with the thumb screws 14 The coil then converts the current to a high frequency alternating magnetic field This magnetic field crosses the metallic conductive work surface e g the frozen nut 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 The more easily magnetized a substance is the greater the heat developed in it That is why the Mini Ductor CE heats ferrous metals and their alloys readily but has no effect on glass plastics wood cloth and other non conductive materials The power switch 12 is used to turn the inverter on and off Push it in 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 Record the serial number from the serial number plate 2 on the inverter to the enclosed Warranty Card and mail to2. Fast Off fast awf ta 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 Frequency free kwuhn see tthe number of cycles or completed alternations per unit time of a wave or oscillation Symbol F Abbreviation freq G F I see Ground Fault Interrupter Glass Blaster glahs glas ta 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 generating 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
3. truck under bed bolts Sensors O7 etc The life of the Preformed Coil can be extended by only heating objects enough to break the frozen rust bond The insulation of the coil will eventually burn through when holding directly to hot nuts A Loosening Corroded Rusted and Frozen Nuts and Bolts 3 4 Step 1 Perform the Preparation for Use instructions Step 2 Push the power switch to activate the Mini Ductor CE Step 3 Bring the Preformed Coil around the frozen nut initially for only two seconds back it away and try to remove the nut with a wrench or socket If it is still frozen apply the Preformed Coil for another two seconds and then try the wrench again There is usually no reason to heat a nut to a red hot condition in order to free it from the corrosion holding it to the bolt VI USING THE U FORM COIL Function The U Form Coil can be shaped to perform any of the previous coils jobs custom part removal and Hail Soft dent removal A Loosening Corroded Rusted and Frozen Nuts and Bolts gt 3 4 Step 1 Perform the Preparation for Use instructions Step 2 Configure the coil to the size nut by wrapping it around a socket piece for that nut Tip The more coil winds you can get the faster it will heat Step 3 Insert both ends of the U Form coil into the electrodes and tighten thumb screws Step 4 Bring the U form Coil around the frozen nut initially for only two seconds back it away
4. The heat created from the Mini Ductor II can ignite the air bag propellant causing it to explode without warning Refer to the vehicles service manual for precise airbag location before operating Personal Safety Rules Continued AA AA 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 Mini Ductor CE Do not replace these items until you are finished using the Mini Ductor CE The Mini Ductor CE 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 Mini Ductor CE The Mini Ductor CE can heat such metallic items very quickly and cause serious burns or even ignite clothing Always wear safety goggles when using the Mini Ductor CE Fi l l if 1 he a 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 PAPER MA
5. and try to remove the nut with a wrench or socket If it is still frozen apply the U Form Coil for another two seconds and then try the wrench again There is usually no reason to heat a nut to a red hot condition in order to free it from the corrosion holding it to the bolt B Heat Shrinking Hail Soft Dents in Sheet Metal Step 1 Perform the Preparation for Use instructions Step 2 Configure the Coil to look like the diagram on the right Step 3 Holding the U form coil 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 U Form Coil 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 U Form Coil from the area This is the point at which the paint will start to bubble Also be careful side view on white and light Crown HailorSoftDent Crown colored finishes these lighter paints tend to yellow sooner than Top View lt Metal darker colors Work in a circle Trouble Shooting If the pirts ot te crows dent doesn t seem to want to shrink this may be ee because there is a crease in the metal or the metal has been stretched to far 1
6. info inductiontools eu iu AEE FOR USE Read and understand all safety warnings and cautions in this manual before operating the Mini Ductor CE A Generator amp Inverter Use The Mini Ductor CE is designed to operate from a normal 230 volt alternating current VAC 50 cycles per second power line or service out let and will operate without suffering damage on voltages up to 240 VAC 1 Generator Some portable generators particularly low cost units producing 4 kW or less are unregulated and can produce in excess of 250 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 Mini Ductor CE 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 kW Prosine 1800 is recommended or larger sine wave inverter The use of square or quasi sine wave inverter will void the warranty Get in contact with info indutiontools eu before using your Mini Ductor CE for instructions on how to proceed if you have any questions regarding the instructions furnished above Using the Preformed Coil Function The Preformed Coil 7 is used to heat nuts fasteners caulking removal frozen door hinges exhaust manifold bolts
7. thereof to be free from defects in materials and workmanship for one year from the date of first purchase excluding all work coils 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 HM Inductiontools will cover ground tran sportation 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 HM Inductiontools 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 given in lieu of any other warranty either expressed or implied including warranties of merchantability and fitness for a particular use HM Inductiontools assumes no responsibility 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 th
8. 0 VII USING THE BEARING BUDDY COIL Function The Bearing Buddy Coil 8 is used to free a race from an axle housing frozen O Sensors remove ball joints amp tie roc ends A Expanding a piece to remove an interlocking part Step 1 Perform the Preparation for Use instructions Step 2 Insert one end of the Bearing Buddy Coil into one of the electrodes and tighten thumb screw Step 3 Wrap the coil at least 3 times around the work piece to be expanded Tip The more coil winds you have the faster it will heat Step 4 Insert the other end into the remaining open electrode and tighten the thumb screw Step 5 Push the power switch to activate the Mini Ductor CE Step 6 Heat until expanded enough to remove the race Step 7 Release the power switch and loosen both thumbscrews to remove the Bearing Buddy Coil Vill USING THE MINI PAD optional Function The Mini Pad 10 is used for removing stickers decals graphics emblems small body side moldings and pin striping A Removing Bonded on parts Step 1 Perform the Preparation for Use instructions Step 2 Insert both Mini Pad ends into the electrodes and tighten thumb screws Step 3 Push the power switch to activate the Mini Ductor CE Step 4 Apply the Mini pad to the end of the desired part to be removed for a couple seconds Once you are able to peel the start of the part off you will have an area you can pull on to keep outward pressures going Re apply the Mini Pa
9. SKS ARE NOT ADEQUATE A WARNING Wear heat resistant gloves when using the Mini Ductor CE The Mini Ductor CE heats metal very quickly You can burn your hands f and fingers when trying to remove parts from hot metal surfaces C Electrical Safety Rules A DANG ER Do not use the Mini Ductor CE in the rain moisture or immerse in water Exposing the Mini Ductor CE to water or other liquids A may cause an electrical shock hazard gr 5 ri Electrical Safety Rules Continued Do not abuse the electrical cord Never use the cord to carry the Mini Ductor CE Keep the cord away from heat oil sharp edges and or moving parts Do not use the Mini Ductor CE if the cord is damaged Cords cannot be repaired only replaced Damaged cords create electric shock hazards Disconnect the Mini Ductor CE power supply cord from the outlet before changing any of the applicators Unplug the Mini Ductor CE from the power supply outlet or cord when not in use D Fire Hazard Safety Rules A ANGER 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 Mini Ductor CE can cause these containers to explode and their contents to ignite Do not use any heating coil if insulation has been breached If insulation has been breached it will cause sparking when contacting with a vehicle This will be a fire hazard especially when working
10. d IMPORTANT Read These Operating and Safety ae Instructions before Using the Mini Ductor CE MINI DUCTOR CE OPERATING AND SAFETY INSTRUCTIONS Specializing in High Performance Induction Heating Systems for the Automotive Aftermarket HM inductiontools Rialex Bv T 31 0 6 43161800 Warehouse and F 31 0 165 552499 Training center info dinductiontools eu Belder 70 www inductiontools eu NL 4704 RK Roosendaal Mini Ductor CE Instruction Manual Copyright O 2010 by HM Inductiontools All rights reserved No part of this document shall be reproduced stored in a retrieval system or transmitted by any means electronic mechanical chemical optical magnetic photocopy printing or otherwise except by written permission of the author or HM Inductiontools No patent liability is assumed with respect to the information contained herein Trademarks Mini Ductor CE is a trade mark ofnduction Innovations Inc All terms or service marks used in this manual have been appropriately capitalized The company Induction Innovations Incorporated can not attest to the accuracy of this information Use of a trademark or service mark in this manual should not be regarded as affecting the validity of any trademark or service mark Warning and Disclaimer of Use Every effort has been made to insure the accuracy and completeness of this manual but no warranty or fitness is implied This information is provided on an as is bases The authors and HM In
11. d to the part working it down the part while keeping outward pressure until the part is completely removed IX Trouble Shooting 1 The Mini Ductor CE inverter is designed to stop running if overheated however the electrodes DO NOT have an overheat shutoff This is why there is a duty cycle with the Mini Ductor Two minutes on two minutes off If the unit stops suddenly check to 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 minutes and then restart If problems contact HM inductiontools info inductiontools eu 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 HM inductiontools info Ginductiontools eu X Disassembly and Storage amp CAUTION Turn unit off and allow the unit and all working coils to cool for at least 30 minutes before disassembly cleaning or storage Handling the unit or parts before they have cooled may result in injury storage of unit while still hot may result in damage to equipment or pose a fire hazard Step 1 When you are finished working turn the power OFF by releasing the power switch and make sure that the internal fan stops 11 Step 2 Disconnect the
12. ductiontools shall have neither liability nor responsibility to any person or entity with respect to any loss or damages direct or indirect arising from use of the information contained in this document 2 Table of Contents Page I Safety RULES mice int 4 7 A General Work Area Safety Rules csssccncccceccceeeceeeeceeeeecees 4 B Personal Safety Rules zuda ra 4 5 C Electrical Safety R l i dotais si a Eh 5 6 D Fire Hazard Safety Rules ss esam sii ss I Haan es 6 E Tool Us Safety K l si adidas dusmas a a 6 7 II ONPON NU ereet iaio dus iisu EEAO 8 A Inductor Mini Ductor CE Components 8 HI Puncipl s Of OPEMUONS disds easosji u es r i rE E E aS 9 IV Preparation tor WSe cccccnacucessacmrsonsncestesacecetcevevseacaaen A as es 9 A Generator amp INv tt t S kl m gsm 9 T Generato oerna a S Ea EA Is 9 ds OV tt fsssendod domteuumuuuss tous E a ss mums sis 9 V Using the Preformed COU s sess saaavseccedvexstvecdedienadazanase seed E tak k mi 9 10 A Loosening Corroded Rusted and Frozen Nuts and Bolts 3 4 10 Vie Using the U Form Com due os ass en ass 10 A Loosening Corroded Rusted and Frozen Nuts and Bolts gt 3 4 10 B Heat Shrinking Hail Soft Dents in Sheet Metal eee 10 VIL Using the Bearing Buddy Com sasaista sesossaea ssp asessscummnnensaateneeeeieates 11 A Expanding a piece to remove an interlocking Part 11 VIII Using the Mini Pad optional 11 A Re
13. e outside Keep a fully charged fire extinguisher at hand at all times when using the Mini Ductor CE B Personal Safety Rules A DANGER PrP Do not operate the Mini Ductor CE and stay at least three feet away from an operating Mini Ductor CE if you have a cardiac pacemaker or any other kind of electronic or metal surgical implant Although the magnetic fields emanating from the tools travel only a few inches they pose a dangerous risk to the proper operation of all implanted medical electronic devices in the user and any bystanders Thus it is necessary that people with electronic or metallic medical implants do NOT use the Mini Ductor CE or come within three feet of it when it is in use in case an accident should occur and the tool in use is inadvertently and unexpectedly brought near the person with the Do hot operate the Mini Ductor CE while wearing any metallic items such as jewelry rings watches chains identification tags religious medals belt buckles body piercing hardware etc The Mini Ductor CE can heat these metallic objects very quickly and cause serious burns or even ignite clothing Do not operate the Mini Ductor CE 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 Mini Ductor CE in unexpected situations Do not use the Mini Ductor CE within 4 inches of any airbag component
14. e 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 HM Inductiontools is not responsible for lost stolen or damaged unit s due to shipping Warranty is non transferable When returning an Inductor Mini Ductor CE all work coils and accessories must be returned with the unit to qualify it for warranty repair contact INFO INDUCTIONTOOLS EU for return authorization prior to shipment 12 XIII Definitions OB OO OOD OOO 909 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 tabbreviation for American Wire Gauge Capacitance kuh pas i tuhns tthe property of being able to collect a charge of electricity Symbol C Celsius selsi s 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 su
15. ed into heat Rosebud rohz buhd ta 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 vohlt tthe 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 Voltage vohl tij telectromotive force or potential difference expressed in volts Watt wot tthe 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 14 My Mini Ductor CE Dealer Company Contact Address My Mini Ductor CE Model Mini Ductor CE Serial Notes Mail to info inductiontools eu
16. h ntreyt ta 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 1 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 Current kur u nt tthe 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 ta unit of measure as of temperature or pressure Eddy Current ed ee kur uhnt tan 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 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 uhd the 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
17. moving Bonded on parts ssssss asas 11 Xe lr9ublesKO0 d ugunis nesa 11 X IBi ass niDiV 4 SLOTAS k zu didas s E EE A SEE Ee 11 12 XI Cleaning TS WC ONS fitness stais E A E ooie cance a 12 Ass Proper Cleaning Cane rigas iii asas desas 12 B Improper Cleaning Care sccescssscpennasysvaennveeisedonnncsdanieadneecccceds ln Sys 12 XI Warranty amp REPAITS xccstes sees se tacecccccssvesnecetesceauacbbbivodoedelsadeaaesaasiccatesnanedseesoncee 12 A Limited AWAEAN GY Gesta man 12 XII IPETNIUONS Zs Daka ads 13 14 XIV Additonal Trainin Sesine ss ASS A IA SI 14 XV My Mini Ductor CE Dealer Information ass 15 This product is covered by patent numbers 6 563 096 and 6 670 590 I Safety Rules for Using the Inductor Mini Ductor CE A General Work Area Safety Rules ts a i F f f ina J 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 Mini Ductor CE These beings may create distractions that cause you to lose control of the Mini Ductor CE 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 th
18. on or near gas lines and or gas tanks E Tool Use Safety Rules Do not leave the Mini Ductor CE unattended when it is ON i l Make sure that the Power Unit has a sufficient supply of air for cooling Make sure that the vents of the Mini Ductor CE Power Unit are clean and free of dust and debris so that the Power Unit has an unimpeded flow of cooling air Do not attempt to repair or service the Mini Ductor CE There are no user serviceable parts except for replacing the coil attachments Before plugging in the Mini Ductor CE 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 Mini Ductor CE Do not twist or bend electrical cord sharply or damage to internal wiring may result Do not use the Mini Ductor CE longer than the duty cycleThe circuit board has an overheat protection device for protection however the electrodes do not have overheat protection Duty cycle two minutes on two minutes off II Components Inverter 2 Serial Plate back U Un a Storage case Not Shown Model Cord amp Plug 220 AC Vent end Preformed Coil work coil Bearing Buddy work coil U Form Coil work coil Mini Pad work coil optional Owners Manual Not Shown Power Switch Electrodes top Thumb Screw L E D
19. plug 11 from the service outlet or extension cord Step 3 Place unit and coils into foam cutouts in storage case XI Cleaning Instructions A Proper Cleaning Care Step 1 Make sure unit is off and unplugged Use a dry clean non abrasive cloth or paper towel to remove grease oil and other dirt from the inverter tools and electrical cords 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 Mini Ductor CE B Improper Cleaning Care Do NOT immerse any components of the unit in water or a cleaning solution S 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 S 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 Mini Ductor CE components Do NOT use heat guns space heaters torches microwave or gas ovens etc to dry the components of the Mini Ductor IIS after cleaning XII WARRANTIES AND OR REPAIRS A LIMITED WARRANTY 1 HM Inductiontools warrants the Inductor Mini Ductor CE and any parts
20. response exhibited by a body in reacting to changes in the forces esp magnetic forces affecting it HF High Frequency hi free kwuh n see tthe range of frequencies in the radio spectrum between 3 and 30 megahertz Inductance in duhk tuhns that property of a circuit by which a change in current induces by electromagnetic induction an electromotive force Symbol L 13 O OS OOO Induction in duhk shuhn 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 InductorB A registered brand name of the only patented induction heating system for the automotive aftermarket Inverter in vur ter ta device that converts direct current into alternating current Kilowatt kil uh wot tunit of power equal to 1000 watts Abbreviation kW kw Ohm ohm the SI unit of electrical resistance defined to be the electrical 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 tuhns ta property of a conductor by virtue of which the passage of current is opposed causing electric energy to be transform
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