CHRIS-MARINE MULTIPURPOSE INDUCTION HEATING TOOL TYPE MPI INSTRUCTION MANUAL Taare FO Box ooes $200 28 Malmoe, Sweden (©Copyright Chris-Marine AB Phone: $46.40.6712600. Fax 448-40 6712609 128)Preface Preface ‘The equipment described within this manual is designed and manufactured by CHRIS-MARINE AB, Malm®, Sweden, ‘The company's principal activities are in the development and production of grinding ‘machines and tools for use in maintenance of diesel engines in the marine, off-shore, power generation and allied industries. ‘Today's machines are the product of experience and R&D since 1962. All Chris- Marine machines have proven performance and are continuously updated to meet the latest standards and demands of diese! technology. Chris-Marine reserves the right to make improvements to the equipment and It's technical documentation. Drawings and diagrams contained within this manual are Intended for illustrative purposes only and are not to scale. Chris-Marine's liability for damages will only be considered, and are strictly limited to use of the equipment and grinding wheels. when operated in ‘accordance and compliance with the appropriate Chris-Marine instruction manual. This manual contains copyright information of the technical nature which is the sole property of Chris-Marine. Neither this complete manual, nor any part, or parts, or sections of the contents, shall be copied, reproduced, scanned or duplicated in any ‘manner without the written consent of Chris-Marine AB, Doc. No.: 1-169-E Rev. 02 2011-11-08 Taare 70. Box 05 5-200 38 tame, Sweden 2028) Phone: 196-40 6712600. ax 4640 6712699 ©Copyright Che Marine ABCi Contents Contents 1. GENERAL INFORMATION. 11. EC declaration of conformity 1.2. Location of nameplate .... 1.3. Safety information 1.3.1. Howto use the manuals. 1.4. Safety precautions .. 15. Safety instructions... DESCRIPTION 2.1. Application and features. 2.2. Technical Data... 3. Function, 3.1. Main parts 3.2. Control Panel Overview 3.3. Generator... 34. Coil 35. HF cables..... 3.6. Foot switch. 3.7. Control panel function and features... 4, INSTALLATION... 4.1. Lifting the equipment... 4.2. Danger zone... 43. Setting up the equipment. PREPARATIONS, 21 5.1. Changing coll... 5.2, Mounting the coil 6. valve seat removal 6.1. Check before start... Start up. 6.3. Manual Mode Operation .. 23 6.4, Auto Mode Operation... 24 6.5. Extraction of valve seat 7. fault conditions... 7.1. Fault finding table Taare PO. Box S005 $.200 39 Maimee, Sweden (©Copyright Chis Marine AB Phone: '+48-40 6712600. Fax: ¥48-40 6712699 3028)GS S- Mane Contents 8. Maintenance... 27 9. circuit diagram 28 4028) ares none: $20039 Malm, Sweden *#86-40 6712600. Fax +46 40 6712699 ‘©copyright Chis-Marine ABGlin Hane General information GENERAL INFORMATION EC declaration of conformity Declaration of Conformity In acordonc with Machinery Directive 2006/42/EC, Amex UA Orettadoe 8 5620039 tno Sweden foc se 4o6r2600 Machine: Mutpupee nto Heating Tel ce 2080 eprint tu Mr Sats ting Many Diete 200 00, ‘tn ptr erect coca te cca so ey set oth Sign oan. mma cncry with LwYteSt RDEIE ate Ete NRE 030 saenaoio sis esau seo saan so tens enc z08 SSinionaaae Ata, cdo, en 45732426, EN 603354200, €N EOS 207, Eeteoe eon fl etobo-¢ 22005, eso00--40b7, Heit 7008 an ‘hs Marin steno ‘5520028 MalmoeSwecen tina Uno o fee ses4oer1 2699 Taress PO. Box S0as '$-200 39 Malmee, Swe (©Copycight Cheie-Marine AB Phone: $$48-40 6712600. Fax: +4640 6712609 5 (28)General information 1.2. Location of nameplate This instruction applies to machinery with details as shown in the nameplate illustrated below. In communication with Chris-Marine AB and their representatives, always state Type and Serial No. of the equipment. Taare FO toa 5-200 39 Malmo, Sweden 628) Phone “46-40 6712600. Fae +46-40 6732699 (Dcopyright Chris Marine ABGiusti General information 1.3. Safety information . How to use the manuals 1 ‘This manual provides instructions to the operator how to use the grinding machine. ‘The manual comprises an introduction section, a descriptive section and an instructive section. A list of spares Is included to the instructive section, in conjunction with ‘maintenance. Addresses to Chris-Marine representatives are placed in conjunction with the list of spares. + Introduction: The Genero! Information emphasises the safety precautions and defines the safety instructions given in the instructive section of the manual. The chapter also displays the Chris-Marine equipment with its nameplate and labels. + Descriptive information: The chapters Description and Function provide an overall description of the equipment, its technical data and performance. + Instructive information: The chapters Installation, Grinding Preparations, Grinding and Exchange of grinding wheel, Trouble Shooting and Maintenance provide instructions on how to handle and — ZAWARNING! This manual must be carefully studied before using the equipment. It will help you to use the equipment to its full capacity and to avoid costly mistakes. All safety instructions must be observed. Failure to do so can result in serious injury or damage to equipment and environment. CChris-Marine AB IN CASE OF ANY DOUBT, CONTACT YOUR CHRIS-MARINE REPRESENTATIVE. Taree FO Box 9005 $200 39 Malmee, Sweden ‘©Copyright Chr Marine AB Phone: 46-40 8712800, Fax. +48-40 6712609 728)Mane General information Ca 1.4. Safety precautions ‘Transportation and installation ‘© The generator must always be handled and stored in the upright position. Ifthe generator is subjected to temperatures below the freezing point of water, the water cooling system must be completely emptied. ‘+ Ensure that the equipment is transported safely. Do not lift above people. ‘+ Do always use the lifting eyebolts when the equipment is lifted. ‘¢ Use undamaged and correctly sized lifting equipment only. Use of the equipment Always use safety goggles and protective gloves when using the equipment. ‘+ Dornot wear wrist watches, finger rings etc, when using the equipment ‘+ People with pacemaker must keep @ distance of Sm to the MPI while It is delivering HF power. ‘+ When the power is on do not touch the col. Always lift it by the junction box + When the power is on do not touch the HF cables. Check that the coated layer on the coilis intact. + Check that cables and hoses are intact. Check that the coated layer on the coilis intact. + The flexible water cooled HF cables connecting the generator to the junction box must not be bended sharply, as, this will obstruct the water flow. Other warnings ‘+ Always tur off electric power supply and water supply when the operation is completed. ‘+ Disconnect the main electric and water supply from the equipment during maintenance, ‘© Do not clean or spray internal parts of the machine with water. ‘+ Do not use the machine for anything but described in the instruction manual. Always use it according to the instruction manual Taare 7, box sos $-20039 Mame, Sweden (28) Phone 46-80 6712600. Fax: 46-406712699 Copyright Chris Marine AB@bnstine General information 1.5. Safety instructions Safety Instructions with important information concerning risks associated with particular operations or recommendations in respect of suitable actions or measures, are included in the text in chapters containing Instructive Information. Three diferent levels of safety instructions, as shown below, are used in the Chris-Marine Instruction Manuals: DANGER! Risk of serious or fatal injury to personnel Safety instructions in this group indicate when there is a risk of serious injury or injury that could cause death as a consequence of WARNING! Risk of injury to personnel and/or damage of property Safety instructions in this group indicate when there is a risk of injury or damage to property or the environment. WARNING! ‘Suspended loads. Do not carry loads above people! WARNING! Flammable substances/products or high temperature WARNING! Hazardous electronic voltage. WARNING! People with pacemaker must keep a distance of 5m to the MPI while it is delivering HF| power. Taaess BO, Box 0025 '$-200 99 Malmce, Sweden ‘©copyright Chris Marine AB Phone: ‘45-40 6712600, Fax: +46-40 6712690 928)1S MARE General information gins CAUTION! Use the equipment correctly Safety instructions in the group indicate that there is a risk of injury or damage if instructions are not followed. Read the instruction manual. Always use approved safety goggles. Always use approved protective gloves. IGNORANCE OF THE SAFETY INSTRUCTIONS OF THIS MANUAL CAN CAUSE ACCIDENTS, WHICH CAN RESULT IN SEVERE INIURY TO PERSONNEL OR DAMAGE TO PROPERTY OR TO THE ENVIRONMENT. Taare PO. Box S07 £20029 Malmo, Sweden 2028) Phones 46-40 6712600. Fax =46-40 6712698 ©Copyright Chri Marine ABDescription 2. DESCRIPTION 2.1, Application and features The Chris-Marine MPI is designed to easy remove worn valve seats from the cylinder head. The equipment consists of an induction generator which generates a high frequency current to an insulated water-cooled induction coll ‘The coll Is designed to fit a specific valve seat centred ‘on the valve guide. Tae coll induces a current to the valve seat which is given a rapid heating, Extra coils can be added to use the equipment for different engine types. The cold cylinder head prevents the valve seat from expanding and after cooling, the seat diameter has been reduced by 0.3 - 0.5 mm. The valve seat can be removed without force. Aaaress BO Box 0005 'S-200 39 Malmee, Sweden Copyright Chris-Marine AB Phone: ++48.40 8712600, Fax: +46-40 6712699 1128)Description Glus RINE 2.2. Technical Data Electrical: Power supply: Max. Power consumption: Max. Inverter Output power: Output frequency range: Cooling Cooling water flow: Cooling water pressure: Cooling water inlet temperature Mechanical Generator cabinet dimensions HW x0: HF cable length: Junetion Box dimensions: Total weight: Operating conditions Ambient temperature: Relative humidity Cooling system (optional) Cabinet diamensions HxWxD: Power supply: Total weight: 12028) Phone 3 x 360-415V 50/60Hz and Ground. (Neutral not required), (816 mm* conductors recommended 44,5KVA_ (3x63A @ 400VAC) 30kW 35-55 kHz Minimum 7 Litres per minute (2 gallons US per minute) Minimum 2,5 bar (0,25MPa, 36 PSI) Maximum 4 bar (0,4 Mpa, 58 PSI) Maximum 35°C (92 °F) Minimum 18°C. (64 °F) 41200 x 600 x 600 mm ( 48 x 24 x 24) Excluding fittings, handles ete, ‘Approx. 1000mm (40") HxWxD: 120180x70 mm (4,7 x3,1 x 2,8") Approx. 100kg (220 Ibs) 5.40% (41-104 °F) Max 85% 810x580%660 mm, 230v, SoH 113 ke 70-890 5-200 39 Malmer, Sweden 446-80 6712600. Fox: 46-406712699 Copyright Chri Marine ABGaetan Function 3. FUNCTION 3.1, Main parts The Valve Spindle Grinding Machine comprises the following main parts and controls Generator Junetion box water-cooled insulated induction coll kt HE cables Footswitch areas PO, Box G02 200 38 Malmoe, Sweden ©Copyright Chrs-Matine AB Phone: +46-40 6712600. Fax. #48-40 6712609 1328)Function 3.2. Control Panel Overview A. Heat power control knob 1. Current 8. Retain power control knob 2. Power Power control switch 3. Frequency D. Operating mode control switch 4. Ught load E, Start button 5. Over volt F. Stop button 6. Over current 2 G. Parameter readout change kW / Amp, 7. Water fall H. Parameter readout change 8 High freq, IL Socket for foot switch connection 9. Low freq J. Elapsed time indicator 10. Power 11. Operate 12. Over current 1 13, Phase fall 14, DC volt fail 415. Heat 36, Retain heat 17. Cooling Taurens FO. Bax Sots 20030 Valmes, Sweden 1s) Phone {46-40 6712600. Fax 46 40 6712609 OCopysght Chr Marine ABRIS MARIME Function 3.3. Generator ‘The generator (1) must always be handled and stored in the upright position. Ifthe generator is subjected to temperatures below the freezing point of water, the water cooling system must be completely emptied. The generator is equipped with wheels to make it easier to move around. 3.4. Coil kit The equipment is delivered with an engine related water-cooled induction coil kit (3). The coll (10) is coated with a special layer which makes the coll isolated fram the engine block when HF power is on. It is important that the layer is intact When handling the coil always lift it by the junction box (2). When not in use place it on the hooks (6) on the generator cabinet. Generator ‘There are different sizes of coils depending on engine type. Some engine types have one coll for inlet seat and one for outlet seat The coil is mounted on a centring equipment consisting of a centre piece (7), 2 guide rod (8), a coil guide (12) and a coll guide nut (13) ‘The coil guide (12) will position the coil in the valve seat and by turning the ut (13) the height can be adjusted to fit the coil at a correct position. Check that the coll Is centered and that there is a few mm distance to the seat. Important: In no place should there be contact between the coll and valve seat! The flexible water cooled HF cables connecting the generator to the junction box must not be bended sharply, as this will obstruct the water flow. Important: The cables should be kept at least 75mm Loki away from the cylinder head or other metallic objects. WARNING! Always check that the coated layer on the 3.5. HF cables coil is intact before use. The HEF cables (A) are connecting the generator tothe Junetion Box. The cables are water-cooled and must not be bended sharply as this will obstruct the water fou WARNING! HF cables must not be bended sharply 36 ‘The cables should be kept at least 75mm away from fie Gal cusiniea te ste He the cylinder head or other metallic objects. Cable ties are mounted around the cables to get a accurate distance between them, They must not be cut off WARNING! Do not touch the HF cables when power is a §.200 38 Malmee, Sweden ©Copyright Cis Marine ABS Phone: +$46-40 6712600, Fax: 45-40 6712699 1528)ARIS MARINE Function Geta 3.6. Foot switch The foot switch (5) can be used instead of the Start and Stop buttons (€) and (F) to activate the HF power. The power is activated as long as the foot switch Is pressed For using the foot switch connect it to the socket (|). When it Is connected the Start and Stop buttons (E) and (F) are deactivated Foot switch 70, ban 50% '5-20039 Males, Sweden 16,28) Phone: 14640 5712600, Fox +46-406712699 Copyright Ors Marine AB1S MARINE Function 3.7. Control panel function and features Digital display: This is used for parameter readout. Which parameter is displayed, will depend on the position of switch C and pushbuttons Gand H. Actuators: ‘A. Controls the output power in the manual mode, and the power in the “Heat” period when in auto mode. B. Controls the output power during the “Retain” period, when in the auto mode. Note: The maximum power obtainable depends fon several parameters. If the maximum value of fone of these Is exceeded, the generator will automatically limit the power to a safe level, and Increasing the power setting will not increase the output power. ._ Selects the output power control mode. In the lower position marked” POW etl” (Used for most applications including valve seat removal) Inverter output power in kW controls the output, and the display readout is in kW. (Approx. min: Tk, Max: 30kW) In the upper position marked "CUR etl” (Used for certain special applications) inverter HF output current controls the output, and the display readout willbe in Amps. D. Selects the operation mode. In the lower position "MAN" the generator will deliver the HF power set by A when “Start” (E) or the foot switch is activated, In the “AUTO” mode the generator will execute the heating cycle preset. (See below). E. Starts HF power If the foot switch is connected, the start switch will be deactivated, and the foot switch will be in control. The generator will deliver HF power as long as the foot switch is activated F. Stops the generator from delivering HF power, respective of all other settings. G Changes the parameter readout on the display. If in the” POW ct!” mode, readout changes from kW to Amperes. If in the “CUR ctl” mode, readout changes from to Amps. to kW. H. Changes the parameter readout on the display to the HF frequency, independently of the power control mode. Optimum operating frequency willbe in the range of 38-50 kHz. 1. Socket for foot switch, J. Elapsed time indicator. The reading advances fone step every second from HF output is started K. Digital switch for heating time (1-99 seconds). L. Digital switch for retain heating time (1-99 seconds}. M. Digital switch for cooling time (1-99 seconds). LED indicators: 4. “Current: Will be lit if the current control mode is selected by C, and HF current output (Amperes) will be displayed. 2. “Power”: Will be lit if the power control ‘mode is selected by C, and inverter HF output (ew) wll be displayed 3, “Frequency”: Will be lit if pushbutton H is activated, and oscillation frequency will be displayed. 4. "Light load”: Will be lit, if heating is started without the coil being placed in the valve seat ‘or not positioned correctly. 5. “Over volt”: Will be lit and the buzzer sound, if the mains supply voltage exceeds 420VAC. Turn of the mains switch and contact @ certified electrician 6. “Over current 2": will be lit and the buzzer sound, if the current in the inverter circuit exceeds the maximum value. Turn of the mains switch. Check the coll and connections. Turn on the mains switch and turn on HE Power If the fault condition persists, contact a service technician. 7. “Water fail”: Will be lit and the buzzer sound, if water pressure/tlow is to low or the cooling water temperature too high Check the cooling water inlet temperature is below 350C, the direction of water flow, and that the inlet pressure is approx. 3 bars (0,3Mpa) at the inlet. Check that the outlet Is not blocked and water is flowing, Please refer to the “Installation” section of this manual. 8 “High freq” : Will be fit and pulsed buzzing sound, ifthe maximum operating frequency is Taras PO. Box 8005 ‘8-200 39 Maimoe, Sweden (Copyright Chie Marine AB Phone: 46-40 6712600. Fax: +48-40 6712609 1728)S Manne Function geste exceeded. Check the coil and connections, 17, Will be lit during the “cooling” period of 2 particulary if there is a short circuit between heating program. ‘the coil windings and/or between coil and valve seat, 9. “Low freq": Will be lit and pulsed buzzing sound, if the minimum operating frequency cannot be achieved. Check the coll and connections, particularly in the Junction box. 10. “Power”: Will be lit whenever mains power is turned on and the generator operational. If it fails to light up, turn of the mains switch and disconnect the mains cable from the mains supply outlet Check that the 3 fuses in the main supply outlet are intact. Unlock the handle and open the back panel of the MPI cabinet. Check that the Magnetic. Circuit Breaker in the upper right section of the inner panel is in the upper ("ON" } position. Check that the 3 fuses (5x20mm), located to the left of the circult breaker are intact. If no faults are found, evontact a service technician Important: Local legislation may require that this procedure must be carried out by a certified electrician. 11. “Operate”: Will be lit/flash and the buzzer sound once every second, whenever a heating process's in progress. 12. “Over current 1°: will be lit/flash and pulsed buzzing sound, if the maximum allowed current in the input supply circuit is exceeded. Turn of the mains power switch Turn the mains power switch on again and restart the heating process. If the fault persists, contact a service technician. 13, "Phase fail": Will be lit and the buzzer sound if the mains supply voltage is too low, or one phase in the 3 phase mains supply is missing Check that all 3 fuses in the mains supply outlet is intact, and the mains supply voltage is above 350VAC. 14, “DC volt fail”: Will be lit and the buzzer sound if the DC voltage supply to the inverter circuit Js missing. Turn of the mains power switch Turn the mains power switch on again. If the fault persists, contact a service technician. 15. “Heat”: Will be lit whenever the generator is delivering HF power. 16. Will be lit during the “retain” period of a heating program, Taare 70. Box 3025 '-200:39 Males, Sweden 38(28) Phone: $8640 6712600. Fae +46-40 6712659 Copyright Chie Marine AB6 Manin Installation 4. INSTALLATION The MPI equipment is delivered as three main pats, a Warning! generator cabinet, flexible water cooled HF cables and a junction box. The generator cabinet is provided with 4 pcs of lifting eye bolts (11). Note! The generator must always be handled and stored in the upright position. If the generator is, subjected to temperatures below the freezing point of water, the water cooling system must be completely emptied, 4.1, _ Lifting the equipment Use only correctly sized and undamaged lifting equipment. For information about weight see chapter 2.3. Lift the equipment by using a sling, fasten it to the lifting eye bolts (11). WARNING! AN Do not carry loads above people. 4.2. Danger zone The danger zone for the equipment when in operation Js an area of 1 m around the equipment. People with pacemaker must keep a distance of 5m to the MPI While iis delivering HFpower. WARNING! People with pacemaker must keep a distance of 5m to the MPI while it is delivering HF power. 4.3. Setting up the equipment Important: Local legislation may require that_this procedure must be carried out_by_a_certified electrician, The temperature on the water inlet must not be over 35°C. 1. Unlock the handle and open the back panel ofthe MPI cabinet. Connect the mains power supply cable to the block terminals located in the upper right corner of the bottom panel (10mm? conductors are recommended). Electrical power Make sure that the mains supply is switched off prior to installation! Ensure that voltage of the machine matches with the supply voltage! See Nameplate Lifting eye bolts Taree POBox 05S 5.200 39 Malimce, Sweden ©Copyright Chris-Marine AB Phone: *$45-40 8712600, Fax +48-40 6712600 1928)Installation 2. Check that the Magnetic Circult Breaker in the upper right section of the inner panel isin the upper ("ON") position. Nominal power supply requirements are 3x380V/SOHz and Ground. However, the MPI will run with 3x360- 415V/50-60He supply. Maximum power consumption Is approx. 42kVA, requiring a mains power outlet of 3x63A if maximum power is required. With 2 mains outlet of 3x35A, about 15kW output power will be available for continuous operation, but 20-25kW may be available for shorter heating cycles, depending on ‘the mains fuse type 3. Close the back panel of the MPI, lock the handle and remove the key. Cooling water: Water inlet is marked by an inlet symbol and blue label, water outlet by an outlet symbol and red label. In general, the MPI will require a water pressure at the inlet of minimum 2,5 bar (0,25MPa). However, do not exceed 4 bars (0,4MPa}, 4, Connect cooling water to the MPI, observe the direction of the flow: * If a cooling system is delivered from CChris-Marine as an optionat equipment connect water inlet and outlet to the MP following the marking. A separate instruction manual is delivered together ‘with the cooling system. © If an existing cooling system is used connect cooling water inlet and outlet using %"/12mm hoses. Insert the short hose with the pressure gauge to the water inlet. 5. Gradually turn on the cooling water supply Lunt the pressure is about 1 bar. Check that no water leak occur in the junction box. Increase the water pressure to 3 bars (0,3MPa) and leave the cooling water supply running for a few minutes, in order to drive out any air left in the cooling system Note! Do not exceed 4 bars (0,4MPa) 6. Mount the front of the junction box again. 7. Check that the mains switch on the front of the MPIis in the “OFF” position. Connect the supply cable to the mains outlet. Water inlet and outlet marking D Inlet woter ec outlet water check that no water leak occur Taare 70, Bar 509 5-200 29 Malmee, Sweden 20(28) Phone: 44640 6712600. Fax +46-405712659 Copyright Chris Marine ABCg Preparations PREPARATIONS ‘The equipment is delivered with an engine related coil There are different sizes of coils depending on engine WARNING! type. Some engine types have one coil for inlet seat Always check that the coated layer on the! and one for outlet seat. Collis intact before use. 5.1, Changing coil 1. Remove the front of the junction box by unscrewing the 4 screws. 2. Mount the appropriate coil for the engine type in the Junction Box. Use the supplied modified 15 mm spanner. Tighten the compression fitting nuts firmly, without using excessive force. 3, Refit the front of the junction box. ‘changing coil ‘The coll assembly is marked on the coil guide. A table fon the Item List shows which coll number is designed for which engine type. 5.2, Mounting the coil 1. Before mounting the coil in the valve seat ensure the coll section is intact. 2. Wipe the area around the valve seat clean in order to prevent smoke, odor and contamination of the coil during the heating process, 3. Ensure the correct coil kit (3) is mounted in the Junction Box (2). 4, Mount the coil in the cylinder head by centering the coll guide (12) In the valve guide. a ‘Mounting coil 5. Check that there are minimum 2-3. mm. distance between the coil windings and the valve seat at all points. f necessary adjust the height by turning the coll guide nut (13). A recommended distance (V) is specified on an assembly instruction delivered with the coll kit designed for the specific engine type. | Important: In no place should there be contact between the coll and valve seat! H Coil height Raters BO Box S005 ‘8-200 39 Malmee, Sweden (Copyright Cnis- marine AB, Phone: ++48-40 8712800, Fax: +45-40 6712609 21 (28)Valve seat removal 6. VALVE SEAT REMOVAL The heating can be done by a Manual Mode or Auto Mode Operation, WARNING! Beware of high temperature on induction heated valve seats, 6.1. Check before start Check before start: 1. Operator must not wear wrist watches, finger rings etc. 2. No persons with pacemaker are within reach of Sm. 3, Induction generator is set up according to chapter 4.3 and the coll is mounted according to chapter 5.2. 4. The HF cables are kept at least 75 mm away from the cylinder head or other metallic objects. 5. Cooling system is connected according to chapter 4.3, 6.2. Startup 1. Start the cooling system and let itrun for a few minutes to allow trapped air to escape. 2. Before turning on the mains switeh ‘Turn the Heat power and Retain power knobs (A) and (8) fully counter clockwise (to minimum). When in minimum the power ‘output will normally be 6.5~7 KW. Set the power control switch (C) in the lower position marked POW Ctl 3. Turn the main switch on. The display will light up and the generator emits a short “Bu22". (If a fault condition occurs, the buzzing will be constant for as long as the fault persists. 4. Start the equipment by one of the following steps: ‘* When using the equipment for the first time on a valve seat for a specific engine type, proceed according to the Manual ‘Mode Operation, ‘© When heating parameters has been established, use the Auto Made WARNING! Always check that the coated layer on the: coll is intact before use. WARNING! HE cables must not be bended sharply as| this will obstruct the water flow. WARNING People with pacemaker must keep a distance of 5m to the MPI while it is delivering HF power. Operation. Taare 7, Bon 025 5.20039 Malmee, sweden 2228) Phone 14640 6712600, Fox +46-406712699 Copyright Chis Marine ABIARINE waste Valve seat removal 6.3, Manual Mode Operation In general, heating should go on, until a temperature WARNING! of about 750°C is reached. At this temperature, the Cee ee eee ee eee color of the hottest part of the seat will be “reddish ‘orange"” For future reference, note the power setting and heating time. 4. Set the mode control switch (0) in the lower position marked Man. 2. Press Start button (E) to turn on the HF power or press the foot switch (5). The HF power is activated as long as the foot switch is pressed ‘The display will show the power output value. Will normally be 6.5~7 kW. ‘©The timer indicator (J) will show the elapsed time in seconds (from 0-99 and ‘then it starts over from 0), 3, Turn the Heat power knob (A) clockwise until desired power is achieved. ‘© The buzzer will sound once every second. ©The maximum power output value will be 15~25 kW, depending on the application, ‘+ Heat indicator (25) willbe tit. ‘© Operate indicator (14) will flash, 4, Press the Stop button (F) to turn off the HF power or release the foot switch (5). ‘© Heat indicator will (15) will go off ‘© Operate indicator (11) will go of 5. Remove the coll fram the valve seat. 6. Leave the cooling water on for at least 30 seconds. Note! Never leave the coil in the seat after heating if the cooling water is turned off. Rates FO, Box S005 '$-200 39 Malmce, Sweden ©copyright Chris-Marine AB Phone +46-40 6712600. Fax. #46-40 6712609 2328)GS nis- MARINE Valve seat removal 6.4, Auto Mode Operation WARNING! In general, heating should go on, until 2 temperature of about 750°C is reached. At this temperature, the Doe ee eee ee ee color of the hottest part of the seat will be “reddish orange”. 4. Set the mode control switch (0) in the upper position marked Auto. 2. Set Heating time {in seconds) on digital switch (W). Press +/- buttons. 3, Turn the Heat power knob (A) clockwise until desired power is achieved. The power Is activated during the Heating time set at switch (K) 4. Set Retaining time (in seconds) on digital ‘witch (L) Press +/- buttons. In many cases this step is not needed. IFnot needed set the time to"01" seconds ("00" is not a valid setting). 5, Tur the Retain power knob (8) clockwise until desired power is achleved. The power is activated during the Retaining time set at switeh (L) If nat needed ensure power knob (8) is set at minimum (fully counter clockwise). (Can be used to extend heating time}. 6. Set Cooling time (in seconds) on digital switch (M). Press +/- buttons. In many cases this step is not needed. if not needed set the time to"01” seconds (*00" isnot a valid setting). 7. Start the heating process by pressing the Start button (E) or the foot switch (5), The buzzer will sound once every second. © Heat indicator (25) will belt. © Operate indicator (1) will flash, ‘© The timer indicator (1) will show the elapsed time in seconds, 8. The process stops when preset time by switches (K), (L), and (M) have elapsed. Stop button (F) can be used to stop earlier 9. Remove the coll from the valve seat. 40. Leave the cooling water on for atleast 30 seconds. Note! Never leave the collin the seat after heating ifthe cooling water is turned off Taare FO tors 5-20039 Malmo, Sweden 24,28) Phone: 446-40 6712600 Fax 45-40 6712699 ©Copyright Chr Marne ABHn MARINE Gustin Valve seat removal 6.5. Extraction of valve seat In general, heating should go on, until a temperature ‘of about 750°C is reached. At this temperature, the color of the hottest part of the seat willbe “reddish orange” WARNING! Beware of high temperature on the induction heated valve seat 1. Ensure safety goggles and protective gloves are used. Specs en cre eter eet Extracted valve seat in woter filed container! the seat after the heating. Optimum seat temperature for extraction isin the range of 50-100°C. 3. important! As soon as the seat has been extracted, wrap the seat in a sturdy cloth, Put the seat ina limited container, preferably filled with water. Ifa fragmentation do occur, it will typically happen within 5 to 20 minutes of extraction. Generally, with smaller dimension seats, no specialized tool will be necessary, Standard extraction tools as used for automotive service purposes, will suffice For larger seats, a customized tool may be necessary. {In most cases, the existing tool used for cold extraction can be adapted, bearing in mind, that the necessary force is only a minute fraction of the force used for cold extraction, WARNING! The heating/cooling process can — depending on alloy ~ ereate high internal stress forces in the seat. These forces may be released, causing the seat to fragment Into several pieces with some force. Taras BO Boo 5-200 38 Malmce, Sweden (€Copyiight Chris Marine AB, Phone: +¥46-40 6712600 Fax +46-40 6712699 25 (28)Fault conditions 7. FAULT CONDITIONS 7.1. Fault finding table |Problem Remedy Indicator 7: Water fail Check the direction of water flow, and that the inlet pressure is approx. 3 bars (0,3Mpa) at the inlet. Check that the outlet is not blocked and water is flowing, Indicator 13: Phase fail heck the mains supply connections and that all3 fuses in the mains installation are intact. No light in any indicator on the control panel: Check that the mains switch on the front isin the on position. Ifso, turn it off Disconnect the mains supply cable at the outlet. Open the back panel of the generator. Check that the Magnetic Circuit Breaker in the upper right section of the inner panel s in the upper ("ON") position. If 0, Check mains supply connections and that all 3 fuses in the mains installation are intact. If the fault persists or other fault conditions occur, please refer to the fault conditions section in the general manual. Raden FO. Box S005 §-20029 Malia, Sweden 26(28) Phone 146-40 6712600. Fax: 46406712699 ©Copyright Chris Marne AB8. MAINTENANCE (Once a year we recommend an overhaul on the water system. Important: Local legislation may require that this procedure must be carried out by a certified electrician Maintenance Taree FO. Box 0005 Copyright Chis Marine AB Phone: ‘$200 39 Malmao, Sweden 48-40 6712600, Fax: #48-40 6712609 27 (28)General touch screen instruction 9. CIRCUIT DIAGRAM iF GENERATOR & aM OR F GENERA Tae FO. bax D0 '5-200.39 Mallee, Sweden 28028) Phone: ‘46-40 6712600. Fc +46-406712699 ©Copyright Chi-Marine AB