Mini-Ductor II Instruction Manual
Contents
1. 12 AIII De finitions Anneal uh neel to heat metals to remove or prevent internal stress Ampere am peer am peer the base SI unit of electrical current equivalent to one coulomb per second Abbreviation A amp AWG abbreviation for American Wire Gauge Capacitance kuA pas i tu ns the property of being able to collect a 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 a 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 6 Current kur u 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 uA nt an electric current in a2. A registered brand name of the only patented induction heating system for the automotive aftermarket nverter in vur ter a device that converts direct current into alternating current Kilowatt kil u wot unit 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 Q Resistance ri zis tu ns a property of a conductor by virtue of which the passage of current is opposed causing electric energy to be transformed into heat Rosebud M rohz buhd a 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 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 1s equal to one watt Abbreviation V Voltage vohl tij electromotive force or potential difference expressed in volts W
3. Com s e OE Pret tena p tien 11 A Expanding a piece to remove an interlocking part 11 VIII Using the Mini Pad optional essere 11 A Removing Bonded on parts sse 11 IX Troubleshootino sieren tte sda dades ts a da 11 Xo Disassembly SOn ER 11 12 Adl Lanne TIS UIC MONS keniana E ae SC eaiodudor s 12 Ae Proper leann C Jte s anata ades tendiba cuti tm dua mda d pedi a cuit 12 D Tmproper t eani Care usse ert etait oi de tetris 12 AIT Winny oR CI AIS aioe a bisce ecu ccu UD T atuaseies 12 A Limited Warranty stus iot miim tede Omaha 12 AUE DENTON se ts estes ected Satie MTE Rea teees 13 14 XIV Additional Tramino 55 on ioc pct REMIS EEEE CoD IR a E ee 14 XV My Mini Ductor II Dealer Information eeeeeeeeee 15 This product is covered by patent numbers 6 563 096 and 6 670 590 I Safety Rules for Using the Inductor Mini Ductor II A General Work Area Safety Rules 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 II These beings may create distractions that cause you to lose control of the Mini Ductor II Work outdoors if there is no dang
4. conducting material that results from induction by a moving or varying magnetic field Electromagnetic Interference i lek troh mag net ik in ter feer u ns Any electromagnetic disturbance that interrupts obstructs or otherwise degrades or limits the effective performance of electronics electrical equipment abbreviation E M I Fahrenheit far u n 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 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 Fast Off fast awf a 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 of or containing iron Flux fluhks The lines of force of an electric or magnetic field Frequency free kwuAn see the 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 Blast
5. to the bolt VI USING THE U FORM COIL M 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 73 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 M 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 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 1n 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
6. Buddy Coil VIII 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 IITM 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 Pad to the part working it down the part while keeping outward pressure until the part is completely removed IX Trouble Shooting l The Mini Ductor II amp 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 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 i
7. att 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 1s available online through I CAR 1 Induction Heaters INHOI TRAINING Training program TA A3 As seen in the I CAR On Line KC pa Induction Heaters www i caronlinetraining com 14 My Mini Ductor II M Dealer Company Contact Address City State Z p Phone Alt Phone Fax Email Website My Mini Ductor IITM Model Mini Ductor II M Serial Please do not forget to complete your product registration at www theinductor com Notes
8. d sharply or damage to internal wiring may result Do not use the Mini Ductor II longer than the duty cycle The 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 Serial Plate back Storage case Not Shown Model Cord amp Plug 110 120 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 4 l oxi H HOT OG IN TN FLAMELESS HEAT SYSTEM 9 Hl PRINCIPLES OF OPERATION The power cord when connected to a GFI outlet 11 insures a properly grounded 120 VAC power input connection The inverter 1 steps up ordinary 120 volt 60 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 whateve
9. e IMPORTANT Read These Operating and Safety W Instructions before Using the Mini Ductor II MINI DUCTOR II 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 2595 Fax 847 551 3369 www theINDUCTOR com Info theinductor com Mini Ductor II Instruction Manual Copyright O 2010 by Induction Innovations Inc 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 Induction Innovations No patent liability is assumed with respect to the information contained herein Trademarks Mini Ductor II is a trade mark of Induction 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 1s provided on an as 1s bases The autho
10. enerator 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 Call Induction Innovations Inc at 877 688 9633 before using your Mini Ductor II for instructions on how to proceed if you have any questions regarding the instructions furnished above V Using the Preformed Coil Function The Preformed Coil 7 is used to heat nuts fasteners caulking removal frozen door hinges exhaust manifold bolts truck under bed bolts Sensors O 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 lt 3 4 Step 1 Perform the Preparation for Use instructions Step 2 Push the power switch to activate the Mini Ductor IITM 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 1t from the corrosion holding it
11. 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 siae view on white and light Crown HailorSoftDent Crown colored finishes these lighter paints tend to yellow sooner than Top View Sheet Metal darker colors Work in a circle Trouble Shooting If the diris oie cee outside of the crown dent doesn t seem to want to shrink this may be Eo om because there is a crease in the metal or the metal has been stretched to far 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 IITM Step 6 Heat until expanded enough to remove the race Step 7 Release the power switch and loosen both thumbscrews to remove the Bearing
12. er glahs glas a 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 tu ruhp ter a 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 tuA ree sis the delay in response exhibited by a body in reacting to changes in the forces esp magnetic forces affecting it HF High Frequency hi free kwu n see tthe range of frequencies in the radio spectrum between 3 and 30 megahertz Inductance in duhk tu ns that property of a circuit by which a change in current induces by electromagnetic induction an electromotive force Symbol L 13 Induction in duhk shuAn the 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 a coil used to introduce inductance into a ferrous work piece Inductor amp
13. er 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 Mini Ductor II amp components Do NOT use heat guns space heaters torches microwave or gas ovens etc to dry the components of the Mini Ductor II amp after cleaning XII WARRANTIES AND OR REPAIRS A LIMITED WARRANTY 1 Induction Innovations Inc warrants the Inductor Mini Ductor II and any parts 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 Induction Innovations Inc will cover ground transportation costs when returning a unit repaired under warranty within the United States 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
14. er 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 Mini Ductor II B Personal Safety Rules A DANGER Do not operate the Mini Ductor II and stay at least three feet away from an operating Mini Ductor II 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 1s necessary that people with electronic or metallic medical implants do NOT use the Mini Ductor IITM 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 i I LI i i i l l Do not operate the Mini Ductor II while wearing any metallic items such as jewelry rings watches chains identification tags religious medals belt buckles body piercing hardware ete The Mini Ductor II can heat these metallic objects very quickly and cause serious burns or even ignite clothing Do not operate the Mini Ductor II while under the influence of drugs alcohol or any medication Do not overreach keep proper
15. footing and balance at all times Proper footing and balance enables better control of the Mini Ductor II in unexpected situations Do not use the Mini Ductor II within 4 inches of any airbag component 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 Lipi ol 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 Mini Ductor II Do not replace these items until you are finished using the Mini Ductor II The Mini Ductor II 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 II The Mini Ductor II can heat such metallic items very quickly and cause serious burns or even ignite clothing Always wear safety goggles when using the Mini Ductor Ir 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 filte
16. 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 Induction Innovations Inc 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 1s 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 amp Mini Ductor II all work coils 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 2595
17. r extension cords except those specified above Unwrap extension cords tightly wrapped extension cords can overheat and cause fires D Fire Hazard Safety Rules 4 DANGER 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 II 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 on or near gas lines and or gas tanks E Tool Use Safety Rules Do not leave the Mini Ductor II unattended when it is ON INIM Make sure that the Power Unit has a sufficient supply of air for cooling Make sure that the vents of the Mini Ductor II V 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 II There are no user serviceable parts except for replacing the coil attachments Before plugging in the Mini Ductor II 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 II Do not twist or bend electrical cor
18. r 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 II 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 1s 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 IV PREPARATION FOR USE g Read and understand all safety warnings and cautions in A this manual before operating the Mini Ductor II A Generator amp Inverter Use The Mini Ductor II M 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 Mini Ductor II have a professional electrical contractor measure the generator voltage with a digital voltmeter Measure the voltage with the g
19. rs and Induction Innovations Inc 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 Table of Contents Page I wis ay RUE AMETE T DUE IT D EE 4 7 A General Work Area Safety Rules eeeeeeeeeeeeeren 4 B Personal Satety RUGS stesso pie t uec tud edt a uoce tomas 4 5 C Electrical Sateb Rules supe ense lu dntiddbqu edidic penses 5 6 D Fire Hazard Safety Rules essen 6 Es LOOM USE Sai ty RU S a ettet ER ER aiio ester AERA ma eis 6 7 II COmpOBe D S ucc tbt edu oiu ob oa ead A duas se celal chicas daly 8 A Inductor Mini Ductor IITM Component eeeee 8 HL Principles OF OC Pera On rues et seta deiode doni Gobsvactu deo e Hau E E b Ure des 9 IV Preparation Or USC outesdtasiostendec iota amid e educ ulta Can Pese eun 9 As enerator oc Inverter US Cis eoe tetas esto mitate M bM em Las dons 9 PEE SI UOI ER 9 DAMM II Lol ERR RETRO TE UT LT 9 Ve Usmeihe Prerormed C OI I Ms od dsc either tte Uo CH Py be oi pode 9 10 A Loosening Corroded Rusted and Frozen Nuts and Bolts x3 4 10 VL Usm the U Portn Gon M s in rette o a rtr ret ere the dan tenues 10 A Loosening Corroded Rusted and Frozen Nuts and Bolts 73 4 10 B Heat Shrinking Hail Soft Dents in Sheet Metal 10 VH Using the Bearme Buddy
20. rs 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 MASKS ARE NOT ADEQUATE Wear heat resistant gloves when using the Mini Ductor II The Mini Ductor II 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 D ANGER Do not use the Mini Ductor II in the rain moisture or immerse in water Exposing the Mini Ductor II to water or other liquids may cause an electrical shock hazard Electrical Safety Rules Continued dla Do not abuse the electrical cord Never use the cord to carry the Mini Ductor II Keep the cord away from heat oil sharp edges and or moving parts Do not use the Mini Ductor II if the cord is damaged Cords cannot be repaired only replaced Damaged cords create electric shock hazards Disconnect the Mini Ductor II power supply cord from the outlet before changing any of the applicators Unplug the Mini Ductor II from the power supply outlet or cord when not in use EXTENSION CORDS If an extension cord is necessary only the following two cord lengths are authorized for use with the Mini Ductor II 25 foot 14 AWG 50 ft 12 AWG 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 othe
21. s 25 ft 14 AWG or 50 ft 12 A WG 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 A 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 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 1s more difficult to remove use generally available nonvolatile automotive interior cleaning products Allow all components to dry completely before using the Mini Ductor II 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 wat
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