GYS Car Duction 33 Owner's manual

Car Duction 33
Induction Heating System
Owner/Operator’s Manual
GYS S.A.S.
Tel : [phone]
www.gys.fr
email : [email protected]

Table of Contents
Electrical conformance documentation i
Safety Precautions 1
Introduction and Warranty 3
Specifications 4
Connections and Utilization 5
Usa e of the Body Pro Inductor 9
Usa e of the Bolt Pro Inductor 10
Usa e of the Glass Pro Induct or 11
Usa e of the Ma nepopper Inductor 15
Routine Maintenance 17
Spare Parts 18
Product Re istration 21

SAFETY PRECAUTIONS – READ BEFORE USING
1
•
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.

SAFETY PRECAUTIONS – READ BEFORE USING
2
FALLING UNIT can cause injury.
• Use handles and have person of adequate
physical strength lift unit.
• Risk of tripping on loose cables.
FLYING METAL OR ADHESIVE can injure eyes.
• Wear approved safety glasses with side shields
or wear face shield.
MAGNETIC FIELDS can affect pacemakers.
• Pacemaker wearers keep away.
• Wearers should consult their doctor before going near
induction heating operations.
OVERUSE can cause OVERHEATING
• Allow cooling period.
• Reduce output or reduce duty cycle before starting to heat
again.
• Make certain all air inlets and outlets are not obstructed.
STATIC (ESD) can dama e PC boards
• Put on grounded wrist strap BEFORE handling boards or
parts.
• Use proper static-proof bags and boxes to store, move, or
ship PC boards.
HF RADIATION can cause interface
• High frequency (HF) can interfere with radio navigation,
safety services, computers, and communications
equipment.
• Have only qualified people familiar with electronic
equipment perform this installation.
• The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from
the installation.
• If notified by the FCC about interference, stop using the
equipment at once.
• Have the installation 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 aware
that some vehicles have airbags in the roof, doors, and the
sides of seats, as well as other locations.
Principal Safety Standards
• Safety and Health Standards, OSHA 29 CFR 1910
SAFETY DEVICES
• When the heater is used frequently, the inductor, the
cables, the electronics and the power transformer become
hot. To prevent the heater from malfunctioning due to
overheating, it is continuously cooled during operation.
The heater is being permanently cooled by air running
through the cabinet. A sensor detects the heat sink
temperature and switches off if the heater is overheated.
• The CARDUCTION is connected to earth. The output of
this equipment is isolated from ground through an internal
isolation transformer.
• The CarDuction is equipped with a 15 amp circuit breaker
(CB1) . If the current exceeds 15 amps, the circuit breaker
will open, interrupting operation.
• Disconnect input power cord from receptacle prior to
replacing fuse, or removing top cover.
• The inductor is insulated to protect the user from electrical
shock.

INTRODUCTION
3
For Professional Use Only
All CarDuction Induction Heating Systems are designed for
professional use only. It is principally designed for
professional mechanics, body shop technicians, auto glass
installers, tradesmen, and journeymen in the performance of
the operations described in this Operating and Safety
Instructions Manual. Use of the CarDuction Induction Heating
System by non-professional personnel and/or operations not
described in this manual is not recommended.
The CARDUCTION is a mobile induction heater, which is used
to heat metallic parts on vehicles without damaging nearby
parts. All other use of the equipment, or use that is contrary to
the instruction in this manual, can cause person injury and/or
machine damage.
Ajax Tocco can in no way be held responsible for intentional or
unintentional damage, and consequent unlimited loss of profit,
loss of income, loss of business opportunity, loss of use or
other similar nuisance, irrespective of how this has arisen, that
originates from incorrect use of this equipment or its use in a
manner not intended.
The CARDUCTION has a versatile working range. For
example, the heater is used for:
• Heating rusted wheel bolts and nuts.
• Paintless Dent Repair (PDR)
• Heating rusted door hinge pins.
• Heat shrinking steel panels during repair.
• Heating of rusted exhaust manifold flange bolts in hard to
reach places.
• Heating of rusted bolts and nuts on the suspension or
steering.
• Easy removal of underseal spay-in bed liners.
• Rapidly curing of adhesives and coatings.
• Easy removal of side moldings, rub stripes, and vinyl
graphics
• Easy removal of windshields, quarter glass and rear
windows.
• Rapidly cure paint and primer
The CARDUCTION is principally designed to heat all magnetic
conductive materials by concentrating a powerful magnetic
field at the end of the inductor. But, the heater also heats
aluminum to some degree. The magnetic field alternates at a
frequency of approximately 50 kHz. The magnetic field
creates eddy currents in the material, and the electrical
resistance creates heat in the metal. The heating 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 be
free of manufacturing defects and shipping damage. All
warranty claims for inductors must be reported within 15 days
after receipt of product.
The guarantee assumes that:
• The equipment is correctly installed and inspected in
accordance with current local regulations.
• The equipment has not been altered or rebuilt without
approval of Ajax Tocco.
• Genuine Ajax Tocco spare parts are used in any repairs.
• Operation and maintenance has been carried out
according to the instruction in this manual.
All claims on warranty must verify that the fault has occurred
within the guarantee period, plus that the unit has been used
within its operating range as stated in the specifications. All
claims must include the product type and serial number. This
data is stamped on the nameplate. All components of the
system must be returned for warranty repairs
All warranty repairs should be returned to Ajax Tocco
Magnethermic, F.O.B. shipping point, for disposition and
repair. Ajax Tocco reserves the right to repair or replace the
defective unit at Ajax Tocco’s discretion.
All warranty and service claims should be shipped to:
GYS
ZI-134, boulevard des Loges
53941 Saint-Berthevin Laval cedex
France
Tél : [phone]
Fax : [phone]
Email :[e-mail]
• IMPORTANT! Read this manual carefully to become familiar with the proper operation of the equipment. Do not
neglect to do this as improper handling may result in personal injury and damage to the equipment.
The drawings in this manual are intended only to be illustrative and do not necessarily show the design of the equipment available
on the market at any given time. The equipment is intended for use in accordance with current trade practice and appropriate safety
regulations. The equipment illustrated in the manual may be changed without prior notice.
The contents in this publication can be changed without prior notice.

Specifications (subject to chan e without notice)
4
Model: OL-441-3.3-50I-00A
Size: 9.25”W X 14”D X 8.12” H
(235mm X 356mm X 207mm)
Weight: 25 lbs (12kg) *power supply 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

Connections and Utilization
5
GENERAL
The CARDUCTION is inspected and checked before leaving the factory to guarantee consistent quality and the
highest possible reliability. Instructions for installation, with general tips and directions,are provided as follows:
WARNING! Do not placethe induction heateron an unstable or uneven ground. The heater
might fall, causing personal injuries or serious damage to the heater.
IMPORTANT! It is the responsibilityof the owner to ensurethat the equipment has been installed
as specified in the instructions provided. It is also the owner’s responsibility to ensure that the
equipment is inspected in accordance with applicable regulations before it is used.
PACKAGING AND DELIVERY INSPECTION
Check the delivery against the packing list, consignment note, or other delivery documentation to verify that
everything is included and in the correct quantity. Checkthe CARDUCTION carefully to make sure that no
damage has occurred during transport. If any part is damaged or missing,the heatermaynot be used until,the
part is repaired or replaced. If anythingis missing, please contact your supplier. Remove all packaging material
from the heater. All shipping claims must be made within 15 days of receipt of the equipment. Do not throw
away the original packaging. Retain the original packaging just incasethe system has to be shipped back to
our factory for future service. Ajax Tocco Magnethermic will not guaranteesafety 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 anIEC C-20 input
receptacle onthe rear that allows different cordconfigurations to be connected. The appropriate power cord
must be connected depending on which line voltage setting will be used. See illustrations below for clarification
of input power cable configurations. Additionally, the copper HF jumper inside the inverter power sourcemust
be properly configured for the appropriate line voltage. Failure to configure the HF jumper can result in un-
warranted damage to the system. See illustration below for configuration details on how to properly configure
the input line voltage of the system. A 120 Vac (NEMA 5-15 cord) is supplied with the system. A NEMA 6-15
240 Vac power cord can be purchased from Ajax ToccoMagnethermic for 240 Vac operation. The socket must
have a good earth ground connection, and it must also be protected with a fuse or circuit breaker as follows:
• The induction power source is shipped with a 15-amp circuit breaker (CB1) installed.
• The induction power source should be connected to a 15-amp, 120/240 VAC, grounded service outlet.
• All CarDuction 33 systems are configured for 230V operation at the factory. Be sure to verify proper
configuration before connecting the system to an electrical supply.

Connections and Utilization
6
The copper HFjumper illustrate above has to be properly configured for the intended input voltagethesystem
will be connected to. Failure to properly configure the HF jumper can result in unwarranted damage to the
system. To relocatedthe jumper, simply loosen the two ¼-20 brass bolts holding the jumper in place. (Do not
completely remove the bolts). Loosen the adjacent bolt totheright or left of the jumper, depending on which
voltage configuration it is currentlyin. Slide the jumper from beneaththe bolts and re-install the jumper in the
alternate position. The center bolt/standoff is always connectedto the jumper. Tighten all bolts after re-locating
the jumper. A schematic illustrating the position of the jumper foreach line voltage is located inthe cabinet next
to the location of the jumper.

Connections and Utilization
7
The CARDUCTION basically consists of an inductor and an inverter power source. A powerful magnetic field is
concentrated inthe inductor when thetrigger isactivated. The inverter power sourcealso contains the control
panel, the main power switch, HF output connector, and foot switch receptacle. Grounding straps are not
required, nor is a warm-up period. The unit is ready for immediate use, once properly connected.
1. Inspect heating inductor (7) for damage. Verifyintegrity of plug, cable,and insulation discard any
heating inductor that issuspect of an unsafe condition.
2. Connect one of the supplied heating inductors (7)to theinduction power source by insertingthe
plug into the HF receptacle (8) locatedon 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 thetop of the plug. Thehole should be orientedupward
when being plugged into the inverter power source HF outlet. There is a safety interlockbuilt into
the heating inductor that will prevent the HF output from being energized if an inductoris not
connected. This is a safety feature that should not be defeated as personal injury or death could
occur.

Connections and Utilization
8
NOTE: See pages 9 through 16 for the inductor descriptions and instruction fortheir uses.
3. Select the appropriate input power cord depending if 120 V or 240 V operation will be used. Inspect
condition of input power cord (4). The insulation should not be cut, burned or spliced. The male
connecting prongsshould not be bent, cut or modified. The unit is provided with a 3 wire grounded
plug. The ground should not be removed or bypassed asthis presents an electrical shock hazard.
Connect input power cord by inserting the C-19 plug (4) intothe C-20 IEC receptacle (5) onthe
back ofthe inverter power source.
4. Configure the copper HF jumper located inside the inverter power source (see diagram on page 6)
for the desired input line voltage that the unit will be connected to. Failure to properly configure the
HF jumper could result in un-warranted damage tothe inverter power supply. A schematic
detailing the proper location ofthe jumper is located just in front of the jumper inside the cabinet.
5. Close circuit breaker CB1(5). Thecircuit breakershould remain closed (inthe on position). If it
doesn’t, stop use immediately and contact customer service for additional instructions. The internal
cooling fansshould be operating at this point.
6. Select the desired maximum output heating power by adjusting the power control knob (9) on the
front of the inverter power source. The heat level is increased as the knob is turned clockwise. It is
generally recommended to start at lower set points, progressing to higher settings as experience
with the tool is gained.
7. Place the connected heating inductor (7) near the metal object to be heated. Depressthe foot
switch (1) briefly. The heat on light (10) should illuminate and the output power meter (11) should
move from the zero position. Stop useimmediately if thefault light (12) illuminates. After verifying
the operation of the induction heating system, continue to use the tool as described in pages 9-16

Body Pro Inductor
9
Theflexible BodyPro Induction pad is usedfor heating sheet metalfor a varietyof applications. When
you first begin using the pad to heat painted sheet metal surfaces, please start with the power level on
Low. Keep moving the pad overthe area to be heated either in acircular or back and forth motion and
check the temperature under the pad every few seconds until you arefamiliar with how fast various
surfaces get hot with your inductor. Remember that you can burn the paint if you are not careful. As
with any new tool, patience and practice will let you increase the power level and speed with which the
inductor helps you to do your job.
Removing decals, vinyl graphics or striping:
Withthe CARDUCTIONset to Low power, slowly move the pad over the item that you wantto remove ina
small circular or back and forth motion. After a couple of seconds, try to lift an edge of the item. If it begins
to lift up easily, then enoughheat has been applied, if not, then apply heat for a couple of more seconds
and tryagain. Older decals, graphics, and striping tend to take more heating time. If you over heat vinyl, it
often gets “mushy” and “bubbly”. Ifthis happens, then letthings cool off some andthen try to lift and peel
the item off. Be careful not to burn the paint! If sufficiently heated the stripes should come off effortlessly
and all 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 sincethe metal underneath the molding is fartheraway 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 motion along the length of the molding. Start at one end ofthe molding and work the
pad slowly back and forth a few inches until you can easilypry the end of the molding loose. Then slowly
move the pad down the length of themolding while peeling the molding free. Try to practiceonscrap
moldings to develop your technique as with any newhand tool. Thetape and adhesive should come off
with the moldings. If glue ortape is left on thepanel, then slow down or increase the amount of heat.
Warming cold body panels:
During the winter monthsin cold climates, acarneeding decals, graphics, orstriping needs to be warmed in
the shopforthe adhesive tostick. Withthe padonthe CarDuction 33, you can quicklyheat just the body
section that you are working on to apply these items. This will save you time instead of waiting forthe panel
to warm up when using conventional methods.
NOTE! Never applypower to an unloaded heating inductor. The bodypanel or metal object tobe
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.

Bolt Pro Inductor
10
The Bolt Pro inductor is used for intense heating of rusted or stuck parts such as nuts and bolts. When
using the Bolt Protip to loosen stuck nuts and bolts, it is OK touse full power to start with. Other uses
include caulking removal from truck beds and trunks of sedans, as well as soldering large electrical
connectors and metal forming.
Removing stuck or rusted bolts:
The Bolt Pro is particularly useful in removing stuck or rusted nuts and bolts. It is better than an oxy-
acetylene torch in several ways:
1. It heats only the metal parts positioned within the gap and without flames that can set fire tothe
many plastic parts in today’s cars. Thus, reduced fire hazards.
2. Unlike the torch which tendsto heat both the nut and the bolt, the Bolt Procan beapplied tothenut
only, heating it and making it expand more than the bolt and thus easier to break loose.
3. The Bolt Pro plugs intothe CarDuction 33, it is light weight and portable, and ready for instant use.
4. It is not necessary to heat fasteners to a red color. In most cases, only mild heat is required to free
the seized fastener. Prolonged exposure of the Bolt Pro Inductor to extreme heat will shorten the
life of the inductor, and could cause un-warranted damage.
5. It isrecommended to maintain an air gap between thebolt pro inductor and the part being heated.
A small piece of welding blanket or fiberglass cloth can beplaced over the jaws of the Bolt Pro
Inductor to help shield it from theradiated heat from thefastener, 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 forhe inductor is 150°.
Bending metal parts:
The Bolt Pro can also be used to rapidly bend small round or flat steel stock for most any purpose.
Soldering large electrical connectors.
First crimp the connector to the wire
Place the barrel of theconnector in the corner of the jaws of the Bolt Pro Inductor.
Apply heat by depressing the foot switch.
Apply solder once sufficiently heated
Shrinking sheet metal:
Place the end of the Bolt Protip onto the area of the sheetmetal to be shrunk. Leave asmall gap between
the tip and the sheet metal if possible. This will help extend the life of thetip. Activatethe switch and heat
the metal to your liking. Tapthe high spot down and cool. Grind area clean prior to shrinking to help
eliminate toxic fumes and smoke.
NOTE! Never apply power to an unloaded heating inductor. The bodypanel or metal objectto be
heated actsas a load to absorb the energygenerated bythe inductor. Without the load, the
inductor will overheat. Overheating the inductorcan cause damage and/or personal injury. The
Bolt Pro inductorshall not be incontact with hot parts for tool long time (temperature max 150 °C).

Glass Pro Inductor
11
Removing a window
1. Remove a reveal molding, ifapplicable. Some windows have encapsulated moldings that can not
be removed. Encapsulated windows can also be removed without damage sincethe CarDuction
only heats metal objects. Some windows have metal moldings, which need to beremoved prior to
applying heat with the CarDuction. The CarDuction will heat the metal nearest to the Glass Pro
Inductor or other heating heads. Ifthe metal trim can’t be removed, itwill be necessary to heatthe
pinch weld from inside the vehicle.
2. Although not always necessary, it is recommended that the interior trim be removedfrom the
vehicle to minimize the possibility of burning the trim. Removal of the interior trim also exposes any
additional hardware such asclips and studs that maybe holding the window in place. Such
hardware will need to be released prior to the removal process. Locating the position of the
urethane bead is also easier with the interior trim remvoved.
3. Disconnect antennas and defroster grids.
4. To prevent scratches to the painted surfacethat could be caused bywooden or plastic wedges,
place a layer of masking tape aroundthe perimeter of the painted surface as close as possible to
the glass or molding.
5. Place a clean layer of masking tape over the pole pieces of the Glass Pro Inductor to prevent
scratching the glass as the Glass Pro is moved back and forth over the glass. Replace the tape
every time another glass is to be removed.
6. Clean the glass thoroughlybefore starting the removal process
7. Always start the removal process near thearea of the vehicle where the repair isto be made. The
greatest risk of paint damage by the wedges is atthestarting point of the glass removal due to the
difficulty of getting thefirst wedge in place. It’s best to start in a corner if possible and progress
around the window towards the undamaged area ofthevehicle.
8. Ideally the Glass Pro Inductor should be placed directlyon top of the urethane for efficient window
removal. However, some vehicles have narrow pinch welds that cause the Glass Pro Inductor to
be too close tothe painted surface, putting unnecessary heat intothe area possiblyburning the
paint. In some cases a damp towel or heat sink compound may need to be applied to absorb the
heat being put intothe painted surface. (See illustrations) If possible, keepthe heating attachment
at least 1 inche away from the edge of painted surface.
9. Generally the urethane is located atthe inner edged of the pinch weld. To locate thepinch weld,
place hand piece of Glass Pro on inner side of window about 4” away, parallel tothe edge or flange
of window opening.
10. Set the unit to maximum output then turnthe unit on and notice the indicator onthe meter located
on the top of the unit. It will move slightly above zero. Slowly move hand piece toward the outer
edge of thewindow (maintain parallel orientation of attachment to edge of glass) and monitorthe
meter asdoing so. The meter will begin to increase as you move closerto the pinch weld. The
more metal that is near the heating attachment,the higher the meter will read. Maximum output
fromthe unit is approximately7 on themeter (The maximum value is affected by theytype of metal
and thickness of the metal). It is not necessary to max outthe meter. Once the meter startsto
increase from its nominal position, move another ¼” (6mm) closer tothe edge. The heating
attachment should be located overthe edge of the pinch weld while maintaining maximum
distance from the paintedsurface. Visually note the distance between theedge of the glass and

Glass Pro Inductor
12
the heating attachment. Maintain the distance as you progress around the window.
11. As previously stated it is best to start in a corner on the same side of thevehicle where the repair
will be made. Start by movingthe heating attachment back and forth about 12 inches on each side
of acornerat arate of about ½inch persecond. Heatingtoo muchof an area is ineffective
because it reduces the amount of heat produced inthe pinch weld. Make about 4 passes overthe
corner. A light trail of vapor/smoke should be visible by this time. Heavy smoke is not good, stop
the process and inspect the vehicle to determine the cause of smoke. Do not breath the vapors.
An external air supplyrespirator is recommended. Hydrogen Cyanide gas is emitted from the hot
urethane, which can be poisonous.
12. Oncethevapor isvisible, you are at the optimal temperature forthe urethane to release. Gentle
outward pressure is required to break the bond. It is possible for it to take several minutes to break
the initial bond of the urethane. Once the bond is broken, the urethane will not re-bond with the
metal. A suction cup can be used in the corner toprovidea location forpulling the glass asthe
pinch weld is heated. Once the corner is lifted, a plastic wedge, suchas the CarDuction glass
wedges can be inserted behind the glass. The wedges provide outward force while heating,
allowing for one man removal of the glass. Be careful. Do not put too much pressure on the glass,
or it will break. Front glass is laminated and is easily cracked. Side and rear glass aretempered
and muchmore durable. Start withrear or side glassfirst then progress to windshields as you gain
experience. It’s best topractice 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 damage that could occur if pressure is applied tothe paint with
the wedge by prying in the opposite direction. Constant outward pressureis necessary to allow the
window to release at the lowest possible temperature. See illustrationsand notes on the next
pages for additional information.
14. Typical removal time for small quarter glass is around 3 to 5 minutes. 10 minutes is not
uncommon. Typical removal time for rear glass and SUV side glass is around 10 to 20 minutes.
Front Glass can be removedin as little at15minutes, but some larger vehicles require up to an
hour to remove front glass.
Removing bonded composite panels to metal, i.e. Camero/Firebird roofs:
Gentlyplace a wood or plastic wedge between the inner and outer panel to beseparated. Looking atthe
panel from a side angle you will begin to notice a slight dimple in the panel, stop, this should be enough,
begin to worktheGlass Pro hand piece over this dimple in a circular motion applying even heat to the
general area. Oncethis dimpled area releases, pushthe wedge in until you seethe next dimple and
repeat. Continue to do so until you reach your objective.
NOTE! Never applypower to an unloaded heating inductor. Thebodypanelor metal object tobe
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.

Glass Pro Inductor
13
Glass Removal Illustration
NOTES:

Glass Pro Inductor
14

Ma nepopper Inductor
15
The Magnepopper heating inductor’s (optional accessory) primary use is for paintless dent repair
and metal shrinking. The Magnepopper emits a strong magnetic field at the tip of the inductor
approximately ½” (13mm) in diameter. The strong focused field from the Magnepopper makes it
possible to remove soft dents of all sizes without damaging the paint. The Magnepopper can
eliminate the need to hire a PDR technician in many cases, saving the shop hundreds of dollars
per car.
It is not necessary to remove the interior trim, because all the work can be conducted from the
outside of the vehicle. Additionally, the risk of damage to the interior is minimal because most
dents are removed at temperatures less than 150F (66C). However, the interior trim should be
removed if metal shrinking is to be conducted, due to the higher temperature requirements.
It is not necessary to drill holes in panels when using the Magnepopper because all the work is
done from the outside of the vehicle.
Although, the Magnepopper does not produce any heat, it is possible to burn the paint if left in
one position for too long. Approximately 3 seconds is the maximum amount of time the
Magnepopper can be held in one location before paint is burned.
The Magnepopper removes dents based on the principles of thermal expansion. The magnetic
field when placed over a dented area causes the metal in that area to become hot. Metal
expands as it gets hot. The surrounding cooler metal constrains the outside of the dented area
that is being heated. The heat causes the 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 the dented area with the Magnepopper inductor.
Over raising the dent stretches the metal in the opposite direction, which prevents the dent from
reappearing when it cools. The area that is over raised will flatten when cooled. It may be
necessary to tap the high area down in some cases.
After raising the dented area, immediately quench the spot with a spray bottle or damp cloth.
This will reduce the likely hood of the metal having memory.
When working panels with many dents, users should not work in one area, but rather move
around the panel heating one area while another cools. This will prevent an oil can effect which
could permanently distort the metal.
Do not over work a dent, because paint damage can occur. 3 to 5 seconds cumulative heat time
is all the paint can withstand before being burned. After heating 3 to 5 seconds, cool the area
thoroughly before heating again. Each time the dent is heated and quenched it is raised a little
more
Dents with creases in them are more difficult. The Magnepopper inductor can remove the dent,
but in most cases the crease is still visible, but can be covered with a little high-build primer and
block sanding.
Dents near the edge of panels or near mechanical details like corners and rain channels are very
difficult to remove with the Magnepopper inductor. Traditional PDR techniques may have to be
employeed.

Ma nepopper Inductor
16
 The Magnepopper can also be used for heating seized nuts in difficult to reach areas, as well as
heating 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.

Routine Maintenance
17
ROUTINE MAINTENANCE
The fault indicator will illuminate due to the following reasons:
Shorted or overheated induction heating coil.
Internal damage to the power source.
If the CarDuction is used in a dustyenvironment, remove the top cover and blow outthe
interior of the cabinet once every2 months
If the CarDuction is routinelytransportedfromsite to site, remove the topcover, inspect and/or
tighten all fastenerswithin the cabinet. Although the Autron has been thoroughly testedfor
transit, fastenerscan become loose and causepossible damage due to overheating and/or
short circuits.
Listen for the operation of the internal cooling fans and veryadequate 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. Dothis daily. Replace or repair cables as needed
Disconnect input power and tighten all internal electrical connections every6 months. Heatingand
cooling of the electricalcomponents from normal use will cause electricalconnectionsto loosen over
time and reduce the consistency of the system.
Inspect the integrity of the HF output connector pins and the pins inside theHF connectors of the
heating inductors once per month. Make sure that all contacts are properly aligned and show no signs
of arcing or burns. Replace the inductors immediately if signs of damage are present. Return the
power supply to thefactory for service is damage is detected.