Professional Documents
Culture Documents
RT-flex Training
Mechanical Features
(RT-flex Specific Parts only)
Chapter 20
Wrtsil Land & Sea Academy
Page
Chapter 20
19-Mar-08
Page
Chapter 20
19-Mar-08
WECS-9520,
E 90 Shipyard
Interface Box (SIB)
on the free end
WECS-9520, E 95
Cylinder Electronic
Unit Terminal boxes
Automatic filter
Supply unit
Page
Chapter 20
19-Mar-08
WECS-9520,
E 90 Shipyard
Interface Box (SIB)
on the free end
WECS-9520, E 95
Cylinder Electronic
Unit Terminal boxes
Automatic filter
Supply unit
Page
Chapter 20
19-Mar-08
WECS-9520,
E90 Shipyard
Interface Box (SIB)
or at the free end
(smaller engines)
WECS-9520, E95
Cylinder Electronic
Unit Terminal boxes
Supply unit
Automatic filter
Wrtsil Land & Sea Academy
Page
Control oil
Pumps
Chapter 20
19-Mar-08
Rail Unit
For engines with more than 7
cylinders, the rail unit is split in two
parts.
Page
Chapter 20
19-Mar-08
Page
Chapter 20
19-Mar-08
RT-flex58T, MKI
RT-flex58T, MKII
Page
Chapter 20
19-Mar-08
Page
Chapter 20
19-Mar-08
Page
10
Chapter 20
19-Mar-08
ICUs
Control
oil rail
Page
11
Chapter 20
19-Mar-08
VCUs
Page
12
Chapter 20
19-Mar-08
ICU, Size 0
Page
13
Chapter 20
19-Mar-08
ICU, Size 1
Page
14
Chapter 20
19-Mar-08
ICU, Size 2
Page
15
Chapter 20
19-Mar-08
ICU, Size 4
Page
16
Chapter 20
19-Mar-08
ICU
Servo oil
return
Fuel control
valves
Fuel side:
The fuel control valves are actuated by pistons in the
control oil block. There is one valve for each injector.
The main body of the ICU includes the injection
quantity piston.
Fuel Quantity Sensor in a housing kept away from
the hot block.
Control- and fuel oil side are entirely separated from
each other. Nevertheless, leakages of both systems
have a common drain.
Servo oil
supply
Working principle:
Each ICU is pre-controlled by 2 or 3 rail valves to
open or close the way for fuel from the rail to the
injection nozzles.
Fuel for each injection, necessary stroke is calculated
and quantified, then injected, measured and corrected
for the next injection.
Fuel side
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17
Chapter 20
19-Mar-08
Fuel Nozzle
Page
18
Chapter 20
19-Mar-08
Page
19
Chapter 20
19-Mar-08
VCU
Valid for flex 58T (MKI),
60C (MKI), 96C-B
Page
20
Chapter 20
19-Mar-08
To exhaust valve
3/2 way valve
Rail valve
Main bearing oil
supply
VCU cylinder
and piston
Connecting
element
Servo oil return
Page
21
Chapter 20
19-Mar-08
VCU piston
HP-hoses to/
from ICU
Page
22
Chapter 20
19-Mar-08
Page
23
Chapter 20
19-Mar-08
Page
24
Chapter 20
19-Mar-08
ICU
Trace heating
Fuel oil rail
Fuel overpressure
regulating valve
VCU
Servo oil
return pipe
Wrtsil Land & Sea Academy
Page
25
Chapter 20
19-Mar-08
VCU
Servo oil
return pipe
Wrtsil Land & Sea Academy
Page
26
Chapter 20
19-Mar-08
Fuel rail:
The fuel rail contains high pressure
fuel of ~ 600 -900 bar delivered by
the fuel pumps of the supply unit
during engine operation. The rail
pressure is regulated depending on
engine load. For each cylinder, there
is an Injection Control Unit (ICU)
installed on the fuel rail. The ICUs
are actuated by help of control oil
pressure. WECS is activating the
ICUs for injection control. The rail is
heated by a trace heating piping
system.
VCUs
ICUs
Fuel rail
Servo oil return pipe
Page
27
Chapter 20
Trace heating
Page
28
Chapter 20
19-Mar-08
SHD-valve
arrangement
Control oil
supply rail
Overpressure regulating
valve:
- Similar function as the
valve used for new design,
but the SHD function is not
included. (fuel drained to
overflow tank)
Control oil
return rail
SHD-valve arrangement:
- The SHD solenoid valve
(energised by Safety
System) enables control air
to the SHD-servo, that
activates the SHD-valve
itself to depressurize the fuel
system. (fuel drained to
overflow tank)
Overpressure regulating valve
Wrtsil Land & Sea Academy
Page
29
Chapter 20
19-Mar-08
VCUs
Page
30
Chapter 20
19-Mar-08
Safety valve
Trace heating
Page
31
Chapter 20
19-Mar-08
Page
32
Chapter 20
19-Mar-08
Page
33
Chapter 20
19-Mar-08
Rail unit general drain piping. Possible leaks of fuel, oil and water are collected for each
rail => Alarm to Alarm System Rail Unit (FWD), General Leak.
The leakage is drained to the sludge tank.
Wrtsil Land & Sea Academy
Page
34
Chapter 20
19-Mar-08
Page
35
Chapter 20
19-Mar-08
Rail Valves
Page
36
Chapter 20
19-Mar-08
Rail valve are quick acting 3/2-way solenoid valves. Each cylinder unit has four
rail valves. Three of them are pre-controlling an ICU, one of them is
pre-controlling the VCU. Flex50 has only two rail valves per ICU.
Following an injection/return- or open/close command of WECS-9520, the
corresponding coils are energized for a very short time (normal operation
~1 ms, max. 4.5 ms), but with a high current impulse (~50-60A).
Iron core
This makes the valve spindle move towards the energized coil
(~0.3 mm stroke).
Valve spindle
The high current impulse and the short travel of the valve
spindle enable a very short actuation time, which is
indispensable for precise injection- or exhaust valve control.
Coils
Page
37
Chapter 20
19-Mar-08
Page
38
Chapter 20
19-Mar-08
Orifice
Double piston
drive
Two exhaust valve
stroke sensors
Joint ring
Measuring cone
Air spring piston
Disc spring package
Exhaust valve spindle
Page
39
Chapter 20
19-Mar-08
Page
40
Chapter 20
19-Mar-08
Page
41
Chapter 20
19-Mar-08
Orifice
Double piston
drive
Measuring cone
Joint ring
Page
42
Chapter 20
19-Mar-08
Orifice
Thrust piece
Double piston
drive
Measuring cone
Two exhaust valve
stroke sensors
Air spring piston
Disc spring package
Exhaust valve spindle
Page
43
Chapter 20
19-Mar-08
Page
44
Chapter 20
19-Mar-08
RT-flex58T-B
RT-flex60C
Page
45
Chapter 20
19-Mar-08
Page
46
Chapter 20
19-Mar-08
Page
47
Chapter 20
19-Mar-08
Page
48
Chapter 20
19-Mar-08
3-lobe cams
Camshaft bearing
covers
Page
2nd intermediate
gearwheel
49
Chapter 20
19-Mar-08
Servo oil
pump drive
gearwheel
and pinions
Page
50
Chapter 20
19-Mar-08
RT-flex60
RT-flex58T
Page
51
Chapter 20
19-Mar-08
Page
52
Chapter 20
19-Mar-08
Page
53
Chapter 20
19-Mar-08
Page
54
Chapter 20
19-Mar-08
Supply Unit
Fuel intermediate
accumulator
Electric actuators
Fuel outlet
to rail
Servo oil
outlet to rail
2nd intermediate
gearwheel
Page
55
Chapter 20
Fuel pumps
19-Mar-08
Shutdown solenoid
valve
Fuel drain
Fuel pressure
retaining valve
Fuel return to
mixing tank
56
Chapter 20
19-Mar-08
Fuel Pump
Page
57
Chapter 20
19-Mar-08
Fuel Pump
Buffer space
Fuel pumps:
Pump cover
Pump cylinder
Pump plunger
Regulating sleeve
Regulating rack
Compression spring
Roller guide
Upper housing
Roller
Page
58
Chapter 20
Lower housing
19-Mar-08
Fuel Pump
Page
59
Chapter 20
19-Mar-08
Fuel Pump
Pos: 5
Half delivery
Pos: 10
Full delivery
Page
60
Chapter 20
19-Mar-08
Regulating Linkage
Fuel pump regulating linkage:
Local position
indication (0-10).
No load indicator !!
Torsional springs
Fork lever
Additional spring to push the rack,
in case of failure, to full position
Page
61
Chapter 20
19-Mar-08
High pressure
pipes
Collector Block
Servo oil
pumps
Oil supply
Page
Chapter 20
19-Mar-08
Suction port
HP-outlet
(Inch-type thread!)
Page
63
Chapter 20
19-Mar-08
Page
64
Chapter 20
19-Mar-08
Page
65
Chapter 20
19-Mar-08
Case drain
Swashplate angle encoder
Visual indication
Proportional
valve solenoidvalves
Proportional
valve position
transmitter
Anti cavitation
inlet (from
servo oil main
supply pipe)
Proportional
valve
HP-outlet pressure
transmitter
Page
66
Chapter 20
19-Mar-08
B,B1
SB
S
P,SP
Rkv
R(L)
Page
67
Chapter 20
Pressure Port
Anti Cavitation Port
Suction Port
Control Pressure Port
Pilot Fluid Drain
Return (Aeration)
19-Mar-08
RT-flex58T, MK1
Page
68
Chapter 20
19-Mar-08
Pressure transmitter
for leak detection
(signal to Alarm System)
Bucher
Page
69
Chapter 20
19-Mar-08
Service Pump
Page
70
Chapter 20
19-Mar-08
Automatic Filter
The automatic filter unit filters the servo (and control-) oil to 6 m.
The by-pass filter has a mesh
size of 36 m.
The filter "sludge" goes back to
the crankcase.
Page
71
Chapter 20
19-Mar-08
The crank angle sensors are located on the free end of the crankshaft (or Geislinger Damper).
The crank angle signal is absolutely indispensable
for engine operation.
At least one of the sensors must be working. If one
fails, WECS-9520 can detect the failure and will
keep working with the healthy signal (plausibility
check). In case both sensors fail, the engine will
stop without delay.
Page
72
Chapter 20
19-Mar-08
CA-Sensor
They are separated from the crankshaft by a special coupling. They create an exact digital signal of the
actual crankshaft position (0.360) The CA sensors have a resolution of 0.1
The spring loaded coupling absorbs all longitudinal and axial movement of the crankshaft. It drives a shaft
which is supported by two ball bearings. The bearings are oil lubricated. From the shaft a toothed belt
drives each sensor.
Shielded BUS cables transmit the signals to the
WECS-9520 control.
Page
73
Chapter 20
19-Mar-08
CA-Sensor
Page
74
Chapter 20
19-Mar-08
CA-Sensor
Connection unit
CA Sensors
Page
75
Chapter 20
19-Mar-08