Clarke IT1500 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS DL1021
1500W INDUCTION HEATER
MODEL NO: IT1500
PART NO: 3400765

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INTRODUCTION
Thank you for purchasing this CLARKE IT1500 Induction Heater.
Before attempting to use this product, please read this manual thoroughly and
follow the instructions carefully. In doing so you will ensure the safety of yourself
and that of others around you, and you can look forward to your purchase
giving you long and satisfactory service.
GUARANTEE
This product is guaranteed against faulty manufacture for a period of 12
months from the date of purchase. Please keep your receipt which will be
required as proof of purchase.
This guarantee is invalid if the product is found to have been abused or
tampered with in any way, or not used for the purpose for which it was
intended.
Faulty goods should be returned to their place of purchase, no product can
be returned to us without prior permission.
This guarantee does not effect your statutory rights.
SPECIFICATION
IP Rating IP20
Operating Voltage 230V ~ 50Hz
Electrical Insulation Class Class II
Rated Input Wattage 1500W
Rated Input Ampage 10A
Instrument Protection Temp. 120°C
Duty Cycle 10 mins. On / 1 mins. Off
Weight 2.40kg
Dimensions (LxWxH) 296mm x 110mm x 167.5mm

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SAFETY SYMBOLS
Read and understand
this instruction manual
before use
Wear Eye Protection
Wear Protective Gloves Wear a Dual Filter
Protective Mask
Class 2 Appliance DO NOT use if you have
an Active Implant
DO NOT touch hot
components
Warning: Risk of Fire
Warning: Risk of
Explosion
Warning: Magnetic Field
Warning: Hot Surface DO NOT use in the Rain
WEEE Directive

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OVERVIEW
When unpacking, check for damage or shortages etc. Any found should be
reported to your CLARKE dealer where the product was originally purchased.
This Induction Heater Kit is supplied with the following components:
1 Induction Heater 5 26mm Tubular Heating Coil
2 U Shaped Heating Coil 6 32mm Tubular Heating Coil
3 Flat Heating Coil 7 Flexible Heating Coil
4 20mm Tubular Heating Coil 8 Hard Storage Case

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ELECTRICAL CONNECTIONS
This product is provided with a standard 13 amp, 230 volt (50Hz), BS 1363 plug,
for connection to a standard, domestic electrical supply. Should the plug
need changing at any time, ensure that a plug of identical specification is
used.
If the colours of the wires in the power cable of this product do not correspond
with the markings on the terminals of your plug, proceed as follows.
• The wire which is coloured Blue must be connected to the terminal
which is marked Nor coloured Black.
• The wire which is coloured Brown must be connected to the terminal
which is marked Lor coloured Red.
We strongly recommend that this machine is connected to the mains supply
via a Residual Current Device (RCD)
If in any doubt, consult a qualified electrician. DO NOT attempt any repairs
yourself.
This symbol indicates that this is a Class II product, and does not require
an earth connection.
WARNING! Read these electrical safety instructions thoroughly
before connecting the product to the mains supply.
WARNING! The wires in the power cable of this product are
coloured in accordance with the following code:
Blue = Neutral Brown = Live
Plug must be BS1363/A approved.
Always fit a 13 Amp fuse.
Ensure that the outer sheath of the cable is firmly held by the clamp
Neutral
(Blue)
Live
(Brown)

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SAFETY PRECAUTIONS
WORK AREA
1. Keep the work area clean and well lit. Cluttered and dark areas invite
accidents.
2. Keep all flammable materials away from the work area.
3. Keep children and bystanders away while working. Distractions can cause
you to lose control and bystanders should be kept at a safe distance from
the working area especially when work is in progress.
4. When using the heater, ALWAYS keep a fully charged fire extinguisher ready
on hand.
PERSONAL SAFETY
1. If you have a cardiac pacemaker or any other kind of electronic or metal
surgical implant, consult your doctor before using this induction heater.
2. Before operating the heater, remove all loose coins, metallic tokens, keys,
chains, pocket knives, miniature tools or any other metallic objects in or on
your clothing. DO NOT replace these items until you have finished using the
heater. This heater can heat these metal articles very quickly, causing
serious burn injuries or even ignite clothing.
3. STAY ALERT, watch what you are doing and use common sense when using
this equipment. DO NOT operate the heater while tired, ill or under the
influence of drugs, alcohol or any medication.
4. DO NOT use the heater within 10cm of any airbag component. The heat
generated by the induction heater can ignite the airbag propellant,
causing it to explode without warning. Before operating the heater, check
the vehicles service manual for precise airbag locations.
5. DO NOT over-reach. Keep your proper footing and balance at all times.
This enables better control of the equipment in unexpected situations.
6. Concentrate on the job in hand, no matter how trivial it may seem. Be
aware that accidents are caused by carelessness due to familiarity.
7. ALWAYS wear safety goggles while using the heater.
8. Fumes and smoke from hot/burning adhesives are toxic. ALWAYS wear a
dual filter respirator mask. Make sure the mask fits. Beards and facial hair
WARNING: THE OPERATOR MUST FOLLOW ALL INSTRUCTIONS WITHIN THIS
INSTRUCTION MANUAL

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may hamper a proper seal of the mask. DISPOSABLE PAPER MASKS ARE
INADEQUATE.
9. ALWAYS wear heat resistant gloves when using the heater. You can burn
your hands/fingers when trying to remove parts from hot metal surfaces.
10. Before working on a vehicle with this heater, ensure the vehicle is well
supported and completely stable. Remember that during body repair,
there is always the possibility of a fixture slipping or a body part failing,
which could cause the vehicle to jolt suddenly. If the vehicle is not
adequately supported, it could fall with possibly serious consequences.
11. NEVER modify this equipment in any way.
12. Check the equipment for damage before use. Any damaged part should
be discarded and replaced. Check for alignment of parts, breakage of
parts, and any other condition that may affect the operation. Any
damage should be properly repaired or the part replaced. If in doubt, DO
NOT use. Consult your local CLARKE dealer.
13. Store out of the reach of children and DO NOT allow persons unfamiliar with
these instructions to use this product.
14. DO NOT use the heater in the rain, moisture and DO NOT immerse it in
water. Exposing the heater to water or other liquids may cause electrical
shock.
15. Disconnect the power supply cord of the heater before changing any of
the applicators.
16. DO NOT twist or bend the electrical cord sharply as it could damage the
internal wiring.
17. DO NOT abuse the electrical cord. NEVER use the cord to carry the heater.
Keep the cord away from heat, oil, sharp edges and/or moving parts.DO
NOT use the heater if the cord is damaged.
18. Unplug the heater from the power supply outlet when not in use.
19. Only use one extension cord with the correct specifications (7.5m, 14-AWG
or 15m, 12-AWG) to work with power tools. DO NOT connect two or more
extension cords in series with each other. Fully unwrap extension cords.
Tightly wrapped extension cords can overheat and cause a fire.
FIRE HAZARD SAFETY
1. DO NOT attempt to heat aerosol cans, paint cans or any pressurised
containers used for storing fuels, compressed gases and liquids. The heat
generated by the induction heater can cause these containers to explode
and ignite the contents.
2. DO NOT use any heating coil if the insulation has been breached, as it may
cause sparks when contacting with a vehicle. This will be a fire hazard
especially when working on or near fuel lines and/or fuel tanks.

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WORK SAFETY
1. ALWAYS make sure the power unit has enough air supply for cooling. Ensure
that the vents of the heater power unit are clean and free of dust and
debris allowing the unit to have an unimpeded flow of cooling air.
2. DO NOT block the power unit fan. The fan is always running when the
induction heater is switched on. It is always cooling the heater to avoid
overheating.
3. DO NOT leave the heater unattended when switched on.
4. DO NOT attempt to repair or service the induction heater yourself. There
are no user-serviceable parts inside the unit.
5. DO NOT use the induction heater longer than the duty cycle (see
Specifications on page 2). The circuit board has a time and overheat
protection device.
6. LED illumination: When turning on the heating switch, the LED light will
switch on too.
7. Overheat Protection: The heater will automatically stop working after ten
minutes of continuous operation due to the overheating protection
device. The LED light will start blinking when the overheating protection
device is becoming active. When the LED light stops blinking you can
continue to work.
8. DO NOT touch the heating coil by hand before the equipment and coil are
not completely cooled off. Coils with high temperatures should be
removed from the heater by means of tools. After the hot coil is removed
from the heater, keep it in a safe place until cold.
PREPARATION FOR OPERATION
Before operating the heater, please read carefully and understand all the
safety warnings and precautions in this manual.
•ALWAYS use a stable output power supply.
USE OF GENERATORS AND INVERTERS
1. Generators: Some portable generators, especially low cost ones with
power of 4kW or less are unregulated and may generate voltages
exceeding 260V, which can damage the heater and invalidate the
guarantee.
2. Inverters, DC to DC converter operation: Use only 3kW or larger sinusoidal
inverters.

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OPERATION
SET UP
1. Evaluate the maximum size of the object to be heated and select the
appropriate heating coil.
2. Making sure the heater is not
connected to a power supply, insert
the heating coil into the heating coil
insertion ports and rotate the locking
knobs clockwise on both sides of the
heating coil to ensure that the coil is
locked in to position.
3. Connect the power plug to a
standard 230V AC outlet. The fan will
automatically start.
4. Place the heating coil to the required
position on the workpiece to be
heated, making sure it DOES NOT
touch the workpiece. Press and hold
down the red heating switch and the
LED indicator lamp will turn on and
the heater will start to heat the coil.
5. When the heated workpiece meets
the required temperature, release
the heating switch (the LED lamp will go off). Place the heater on a flat
secure area away from any flammable materials and keep the fan
working for approximately 15 minutes before unplugging the heater.
CAUTION: PLEASE SELECT AND INSTALL THE HEATING COIL IN STRICT
ACCORDANCE WITH THESE OPERATING PRINCIPLES AND PROCEDURES BEFORE IT IS
ENERGISED. AFTER THE HEATER HAS BEEN SWITCHED ON, THE HEATING COIL

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INSERTION PORT AND COIL SHOULD NOT BE TOUCHED BY HAND UNTIL
COMPLETELY COOLED DOWN.
USE OF THE TUBULAR HEATING COILS
• Function: The tubular heating coils (4,5 &
6 in the Overview on page 4) are used to
heat nuts, mechanical bolts, fasteners,
frozen door hinges, exhaust manifold
bolts, truck bed bolts, sensors (O2) etc.
NOTE: The service life of the tubular heating
coils can be prolonged by heating
the workpiece enough to disassemble without excessive heating.
During the heating process, the heating coils SHOULD NOT touch
the workpiece and heated object. If the temperature of the
workpiece is too high, the insulation layer of the coil may burn
out.
CAUTION: TO PROTECT THE FIBREGLASS INSULATION ON THE COILS DO NOT HEAT
UP THE WORK PIECE TO THE POINT IT IS GLOWING RED.
Loosening frozen, rusty, corroded screws and
nuts:
1. Follow the instructions for preparation of
operation and set up on page 8.
2. Press the heating switch to start the heater.
3. Place the related coil around the nut,
initially for two seconds only, pull it back
and try to remove the nut with a wrench or socket set. If it is still tight, apply
the coil for another two seconds and then try to unscrew again. Usually,
there is no reason to heat a screw/nut/bolt up to red hot condition in order
to remove the corrosion from the bolt.
USE OF THE U SHAPED HEATING COIL
• Function: The U shaped heating coil (2 in
the Overview on page 4) can perform
any work of the other coils and can be
customised to remove and repair dents.

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Remove and repair of dents:
1. Follow the instructions for preparation of
operation and set up on page 8.
2. Bend the coil in the way that looks like the
drawing on the right and relevent to the size of the dent.
3. Press the heating switch to start the heater.
4. Place the coil 12 to 25 mm
above a dent and move the
coil in small circular motions
inward around the outside of
the crown of the dent. If the
dent shrinks, pull the heating
coil back quickly and cool
the dent with a damp cloth.
If the dent sucks in, then you
are heating the crown, or
you are not far enough from the outside of the crown of the dent.
5. Repeat the procedure until the dent is removed to your satisfaction.
NOTE: Should smoke appear from the dent, immediately remove the
coil. At this point, the paint will start to bubble. Also pay attention
that white and light colours tend to become yellowish earlier
than dark colours.
NOTE: In case the dent does not seem to shrink, it may be caused by a
crease in the metal or the metal has been distorted too much.

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USE OF THE FLEXIBLE HEATING COIL
• Function: The flexible heating coil (7 in
the Overview on page 4) is used to clear
a bearing from an axle housing, frozen
O2 sensors, remove ball joints and tie rod
ends.
Expanding a piece to remove an interlocking
piece:
1. Follow the instructions for preparation of
operation and set up on page 8.
2. Insert one end of the flexible coil into the
one of the heating coil insertion ports and
tighten the locking knob.
3. Wind the coil at least 3 times around the work piece to be expanded,
making sure that the coil DOES NOT touch the work piece.
NOTE: It will heat faster as more coil is wound round the workpiece.
4. Insert the other end of the flexible heating coil into the remaining insertion
port and tighten the locking knob.
5. Press the heating switch to start the heater.
6. Heat until the workpiece has expanded enough to remove the bearing.
7. Release the heating switch and loosen both coil locking knobs to release
the heating coil.
USE OF THE FLAT HEATING COIL
• Function: The flat heating coil (3 in the
Overview on page 4) is used for
removing stickers, graphics, decals,
emblems, small body side mouldings and
pin striping.
Removing graphics:
1. Follow the instructions for preparation of
operation and set up on page 8.
2. Press the heating switch to start the heater.
3. Apply the flat heating coil near the end of
the related piece to be removed for a few

13
seconds, making sure the coil DOES NOT touch the work piece. Once you
can peel off the end of the piece, you will have an area to pull on.
Reapply the flat coil to the piece, working it down the piece while keeping
outward pressure until the piece is completely removed.
TROUBLESHOOTING
1. During the heating process of less than 5 minutes continuous working
(measured baseline is the time from pressing to releasing the heating
switch), the LED light changes from constantly lit up to blinking, indicating
that the heater will stop heating due to entering the protection mode /
duty cycle.
2. If the heater is overheated or overloaded during the heating process, the
heater will automatically stop heating and enter the protection mode. at
this moment, the LED light will starting blinking. Release the heating switch,
the cooling fan will continue to work. Place the heater in a safe place and
wait a few minutes until the LED light is constantly on. The state of the LED
light is controlled and can be followed by the heating switch.
3. If there is a lack of power output, this might be from using an improper or
damaged extension cord. The correct gauge and length of the cord is
7.5m, 14-AWG or 15m, 12-AWG. Use only one extension cord at once.
4. During heating up, smoke may occur at the head of the heating coil due
to high temperature. This is a normal phenomenon.
5. The heating coils are consumables. If the outer skin of the coil falls off in a
large area after use, it is recommended to replace the heating coil by a
new one. DO NOT use external or self-made coils to avoid damage of the
equipment and prevention of accidents.
DISASSEMBLY AND STORAGE
After releasing the heating switch, the fan will continue to work for at least 15
minutes until all components and the working coil are completely cooled down.
1. When the work is completed, release the heating switch to ensure the
continuous operation of the fan.
2. Place the heater on a solid flat surface, well away from any flammable
materials as coil and heater will still be hot.
3. Disconnect the power outlet and press the heating switch to ensure that
the internal fan stops.

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4. After the heater has cooled down (approximately 15 minutes), release the
locking knobs and remove the coil, making sure the coil is cool to the
touch.
5. Replace heater and heating coils back in the storage case and store in a
safe place.
6. While disassembling, if necessary, replace the heating coils immediately
after a heating operation to be ready for the next heating operation.
CLEANING GUIDANCE
PROPER CLEANING AND CARE
1. When cleaning, make sure that the unit is switched off and unplugged. Use
a dry, clean, non-abrasive cloth or paper towel to remove grease, oil and
other dirt from the housing, tools and electrical cords before returning them
into the storage case.
2. For more stubborn grease, oil and dirt, use a generally available
non-volatile automotive interior cleaning product. Allow all components to
dry completely before using the heater.
IMPROPER CLEANING AND CARE
1. DO NOT immerse any components of the unit in water or cleaning solutions.
2. DO NOT spray the unit with a stream of water from a hose or wash any parts
under a stream of water from a tap, hydrant or shower.
3. DO NOT clean any components with volatile organic compounds such as
petrol, benzene, kerosene, vanish remover, fuel oil, methyl ethyl ketone
(MEK), brake part cleaner, plastic adhesive solvents, paint remover and
thinners, etc. These substances are fire hazards and will harden or dissolve
the polymer materials used in the components of the heater.
4. DO NOT use torches, space heaters, heat guns, gas ovens or microwave
ovens, etc. to dry the components of the heater after cleaning.

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DECLARATION OF CONFORMITY