20 rt flex comp syst

7/30/2019 20 RT Flex Comp Syst

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RT-flex TraininMech. Components & Hydraulic systems

- ex pec c ar s on y

Wrtsil Land & Sea Academy Page 1 Chapter 20 Feb. 2010

Rev. 1Feb. 2010


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RT-flex Comp. & Systems RT-flex specific parts only



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RT-flex Comp. & Systems Overview RT-flex50

Rail Unit(s)WECS-9520,E90 Shipyardnter ace ox

on the free end

WECS-9520, E95Cylinder ElectronicUnit Terminal boxes

Automatic filter



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RT-flex Comp. & Systems Overview RT-flex58/60

Rail Unit(s)WECS-9520,E90 Shipyardnter ace ox

on the free end


Automatic filter



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RT-flex Comp. & Systems Overview RT-flex82C/82T

Rail UnitWECS-9520,E90 Shipyard

on the free end

Automatic filter


Servo supply unit


Fuel supply unit


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RT-flex Comp. & Systems Overview RT-flex84/96

Rail Unit(s)WECS-9520,E90 Shi ard

Interface Box (SIB)in the middle or

at the free end (up

WECS-9520, E95Cylinder Electronic

Unit Terminal boxes

Supply unit


PumpsAutomatic filter


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RT-flex Comp. & Systems Automatic Filter RT-flex50

For the servo oil systems normal system

system for easier operation andmaintenance. One branch of the mainlube oil pipe is connected to theautomatic filter. The automatic filter hascartridges of nominal 6 m where the by-pass filter has a mesh size of 36 m.

The filter "sludge" goes back tothe crankcase.



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RT-flex Comp. & Systems Automatic Filter RT-flex82Filtered Oil

For the servo oil systems normal

to Servo Pumps

sys em o s use ns ea o a separa ehydraulic system for easier operation

and maintenance. One branch of themain lube oil i e is connected to theautomatic filter. The automatic filter hascartridges of nominal 25 m where theby-pass filter has a mesh size of 36 m.

Back flushingto crankcase


Oil Inlet fromMain Bearing Oil


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RT-flex Comp. & Systems Automatic Filter

The back flushing is automatically initiated by the control box either

A) standard: Time controlled (after 1 hour)

B) or: if the differential pressure across the filter becomes too high (0.35 bar)

The filter "sludge" goes back to the crankcase. It is filtered system oil which is clean enough fornormal use.

In the filter control box the back flushing is initiated either by time or differential pressure. Flushingcycles are counted. Failure messages are generated if necessary (Overcurrent, differentialpressure high etc. )

There are switches/buttons to switch from Operation to Adjust. For detailed information pleaseconsult filter makers manuals.



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RT-flex Comp. & Systems Supply Unit Drive RT-flex50

Single lobe drive

The supply unit is direct driven by the crankshaft.e servo o pumps are r ven y n v ua p n ons,

having a mechanical fuse (reduced diameter in pinion),in order to protect the gear-drive in case of a pumpseizure.Since the supply unit, i.e. fuel pumps and servo oil pumpshave no timing, means they just supply fuel or oil, thecamshaft does not have to have a determined position


compared to crankshaft. However the position of the

cams relative to each other must be respected.

MM, chapter 5552


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RT-flex Comp. & Systems Supply Unit Drive RT-flex58/60

RT-flex58T-B RT-flex60C


MM, chapter 5552


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MM, chapter 5552


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MM, chapter 5552



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RT-flex Comp. & Systems Supply Unit Drive RT-flex84/96

The supply unit is driven by the crankshaft, viatwo intermediate gearwheels.

3-lobe camsSupply unit gearwheel

Drawn for Size 4

3-lobe cams are mounted to the camshaft.

The servo oil pumps are driven by individualinions, havin a mechanical fuse (reduceddiameter in pinion), in order to protect the gear-drive in case of a pump seizure.

Since the su l unit, i.e. fuel um s and servo

oil pumps have no timing, means they just supplyfuel or oil, the camshaft does not have to have adetermined position compared to crankshaft.

Camshaft bearingcovers

each other must be respected.

Servo oil

gearwheeland pinions2

nd intermediategearwheel


MM, chapter 5552


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RT-flex Comp. & Systems Supply Unit RT-flex50

Fuel s ide: The jerk-type fuel oil pumps deliver fuel

o e ue ra . o eep e ra pressure(600 - 900 bar), the pump flow rate is

regulated via electric actuators, byressure set oint si nals from WECS- 9520.

Servo oil side: The D nex servo oil um s deliver oil to

ue umps

the servo oil rail with a pressure of ~100- 200 bar via rising pipes.

The number of fuel- and servo oil um s depends on the number of cylinders.

.

Servo oil Pumps



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RT-flex Comp. & Systems Supply Unit RT-flex58/60

RT-flex60

- ex



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RT-flex Comp. & Systems Fuel Supply Unit RT-flex82

The fuel supply unit is driven by the crankshaft,

ue umpse nzmannFP Actuators

-Devices

.

One-lobe mono block camshaft.

ams a t ear ng cover as spec a es gnin order to seal camshaft casing from gearwheel casing (crank casing).

Since the supply unit, i.e. fuel pumps andservo oil pumps have no timing, means they just supply fuel or servo oil to Rail Unit, thecams a oes no ave a e ermne pos oncompared to crankshaft. However the positionof the cams relative to each other must beres ected for load sharin .

The number of fuel pumps depends on thenumber of cylinders.

CamshaftGear

Other CamshaftBearings

CamshaftCasing Drain


#2 CamshaftBearing


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RT-flex Comp. & Systems Fuel Supply Unit RT-flex82

Fuel Return Line High Pressure Fuelto RU Fuel Rail

Fuel PressureRetaining Valve

HeinzmannFP Actuators

Fuel Inlet fromBooster Pump

and Linkages

The jerk-type fuel oil pumps deliver fuel into the RU fuel rail pipe directly

The pump flow rate is regulated by electric actuator to keep the rail pressure (~ 500 - 1000 bar)

Actuators are receiving position set point signals from WECS-9520



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RT-flex Comp. & Systems Servo Oil Supply Unit RT-flex82

The Servo Oil supply unit is driven by thecrankshaft, via an intermediategearwheel.

Dynex ServoOil Pumps

The servo oil pumps are driven byindividual pinions, having a mechanicalfuse reduced diameter on carried shaftbetween pinion gear and servo pump), inorder to protect the gear-drive in case of a pump seizure.

Mechanical

Driven Gear byIntermediate Gear


Driving Gea to

Pinion Gears MM, chapter 5552


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RT-flex Comp. & Systems Servo Oil Supply Unit RT-flex82

High PressureServo Oil to

Servo Oil Inletfrom Automatic Filter

Servo Oil InletFlow Sensors

Pressure ControlValves

# 1 # 3

The servo oil pumps are made by Dynex. They deliver servo oil into RU servo oil rail pipe witha pressure of ~ 100 - 200 bar directly via rising pipes

The pressure control valves receive pressure set point signals from WECS-9520


The number of servo oil pumps depends on the number of cylinders


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RT-flex Comp. & Systems Supply Unit RT-flex84/96 Dynex



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RT-flex Comp. & SystemsFuel intermediate

Supply Unit RT-flex84/96 Bosch

Fuel s ide: The jerk-type fuel oil pumps deliver fuelinto the intermediate accumulator. To keep

-

accumulator

Fuel outletElectric actuators ,

flow rate is regulated via regulating linkageand el. actuators, by pressure set pointsignals from WECS.

Servo oil collectorblock

From the accumulator there are two outlets,connecting the accumulator to the fuel rail

.

Servo oil side: The servo oil pumps are made by Dynex or Fuel um s

Servo oilosc . ey e ver servo o n o servo o

collector block with a pressure of ~ 80 -190bar. There are two outlets from the collectorblock connectin to the servo oil rail via two

rising pipes.

The number of fuel- and servo oil pumps Servo oil pumps nd


epen s on e num er o cy n ers. (shown here as Bosch) gearwheel


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RT-flex Comp. & Systems Supply Unit RT-flex84/96

S ut own &overpressureregulatingvalve

u own so enovalve

Fuel drain

Fuel pressureretaining valve

Fuel return tomixin tank

Fuel inlet frombooster unit


two safety valves (1250 bar).


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RT-flex Comp. & Systems Fuel Pump

Fuel pumps: The jerk-type fuel pumps deliver a variable

u er space

Non return valve

and fuel rail, in order to maintain the demandedrail pressure.

They do not have any timing. Pump plunger

Pump cylinder

To change the feed quantity, the pump plungeris turned by the regulating rack. Regulating rack

Compression spring

Regulating sleeve

sleeve are lubricated by main bearing oil via adouble orifice.Roller guide Upper housing

Lower housingRoller

Wrtsil Land & Sea Academy Page 27 Chapter 20 Feb. 2010 MM, chapter 5556


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RT-flex Comp. & Systems Fuel Pump

Plunger posit ion at regulating linkage posit ion:

Pos: 0 Pos: 5 Pos: 10No delivery Half delivery Full delivery



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RT-flex Comp. & Systems Regulating Rack RT-flex50Fuel um re ulatin :

The regulating rack is moved by Woodward (ProAct IV) electric actuators. They receive a position setpoint signal from WECS-9520 (4-20mA Signal).

ac ac ua or con ro s one ue pump e arrangemen o ac ua ors can er among eng ne cy n ernumbers).

Air dam er

future RT-flex50 engineswill get a Heinzmann

. .

needed!

Woodward electric fuelpump actuator



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RT-flex Comp. & Systems Fuel Pump Actuator Heinzmann

Fuel pump regulating:

The fuel pump regulating rack is moved by.

One(1) actuator regulates one(1) fuel pump.

Actuators (Control Modules) receive a position setpoint signal from WECS-9520.

.

Max. Delivery


Control Module for Actuator


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RT-flex Comp. & Systems Regulating Linkage

Fuel pump regulating linkage:

The regulating linkage is moved by Woodward

Electric fuel pump actuators

.position set point signal from WECS-9520.One actuator controls two fuel pumps (thearran ement of actuators can differ amonengine cylinder numbers).

The torque from linkage shaft to fork lever is

springs. If a regulating rack of a pump is stuckfor some reason, the springs will compensate,so the other pump can still be regulated.Local osition

indication (0-10).No load indicator !!

Torsional springsFork lever

Additional spring to push the rack,in case of failure to full osition



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RT-flex Comp. & Systems Fuel Overpressure Regulating Valve

Fuel overpressure regulating valve:

accumulator rises to ~1050 bar, theoverpressure regulating valve releases fuel to

the fuel return line. The opening pressure is pre-adjusted by valvemanufacturer. Shims are used to give the rightposition to the knurled screw, means if the screw

,

(

for RT-flex84T-D and 96C-B see ServiceLetter RT-flex-07/07 ).

e mn. openng pressure, means w en nur escrew is screwed fully out, is around 500 bar(engine still operational).

pressure keeps the valve closed. When theopening fuel pressure is reached, main bearingoil is released, pressure above piston drops and


ue s re ease .

fl h d l


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RT-flex Comp. & Systems Shutdown Valve RT-flex84/96

ShutdownSolenoid

Oil filter

o eno va ve eadrainEngine shutdown function:

A shutdown is initiated by energizing thevalve

MB-oilsupply

so eno va ve energ ze rom safetysystem , not WECS). In this way, mainbearing oil pressure above piston is

Lever for-

Piston

down engine stops

pressurisingfor mainte-nance work


MM, chapter 8750


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RT fl C & S t S l U it S Oil


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RT-flex Comp. & Systems Supply Unit, Servo Oil RT-flex84/96

ervo o pumps arrangemen : The servo oil pumps supply oil to the collector block, which has two high pressure outlet pipes to theservo oil rail. A safety valve limits the max. pressure to 230 bar.

The number of servo oil um s de ends on the number of c linders. If one um fails the en ine can still be operated.

Non return valvesSafet valveFlow sensor

at each inlet

High pressurepipes

Collector Block

Oil supply Servo oilpumps

Wrtsil Land & Sea Academy Page 35 Chapter 20 Feb. 2010Dynex pumps arrangement

Bosch pumps arrangement (some engines only). MM, chapter 5552


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RT flex Comp & Systems Servo Oil Pump Dynex


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RT-flex Comp. & Systems Servo Oil Pump Dynex

HP-outletAdjustable Outlet oil flow

("compensator valve") of Dynex pump

screw

,corresponding to

min. required outletpressure

PistonOil

Control drain

0 - 2.5A 24V DCPump shaft and Bypass outlet /

inlet

60 100Hz(PWM)

.

Pump outletControl circuit

safety valve

Proportionalsolenoid with

overpressuresafety valve


adjustableend stop

RT flex Comp & Systems Servo Oil Pump Bosch RTflex84/96


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RT-flex Comp. & Systems Servo Oil Pump Bosch RT-flex84/96

The Bosch servo oil pumps are axial piston swashplate type pumps. They supply oil to the collectorblock and via two high pressure pipes to the servo

. .bar.

The number of servo oil pumps depends on thenumber of c linders. If one um fails, the en inecan still be operated.When the engine turning direction is reversed, theswash-plate of the pumps needs to be reversed as

.

Control oil is used to move the swash plate toposition.


RT flex Comp & Systems Servo Oil Pump Bosch RTflex84/96


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Swash plate angle encoder High pressureoutlet

Control oil inlet Leak oil returnCase drainVisual indication

Non returnValve / anti-cavitation ort

Proportional

Proportionalvalve solenoid-valves

Anti-cavitationinlet (from

transmitter

servo o ma n

supply pipe)Proportionalvalve

HP-outlet pressuretransmitter


RT-flex Comp & Systems Servo Oil Pump Bosch RT-flex84/96


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The Bosch-Rexroth pumps have its ownregulating system, getting pressuresetpoint signals and ahead/astern signalsrom .

The anti-cavitation port avoids cavitationin the pump body, if a pump does notmove the swash late to the a ro riateengine running direction. (pump tries tosuck in from HP-outlet pipe).

In such a case the non-return valve atanti-cavitation port opens. Servo oil frommain supply pipe is sucked in via anti-cavitation port and delivered out again

" " .through the pump.

This is default in case of black out, the B,B1 Pressure Port SAE 1 1/2 ""

to prevent servo oil overpressure due towindmilling engine without servo oilconsum tion.

S Suction Port SAE 3 "P,SP Control Pressure Port M18x1.5Rkv Pilot Fluid Drain M22x1.5


RT-flex Comp & Systems Control Oil Pumps RT-flex58/60 MKI


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RT flex Comp. & Systems Control Oil Pumps RT flex58/60, MKI

RT-flex58T, MK1


RT-flex Comp. & Systems Control Oil Pumps RT-flex84/96


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RT flex Comp. & Systems Control Oil Pumps RTflex84/96

HP-Inlets from pumps

Drain valve for leakage (with orifice)

3 shut of valves for outlets

Two Pressure retaining valves

raus mmer

Two Overpressure relief valves

Pressure transmitterfor leak detection(signal to Alarm System)

2 (3) HP-outlets for double wall->

Bucher


RT-flex Comp. & Systems Service Pump


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RT flex Comp. & Systems Service Pump

Applied on engines without control oil system like RT-flex50,flex58TB/60C MK II , flex68B and flex82 to pressurise servooil rail in standstill for testing reasons


RT-flex Comp. & Systems Rail Unit RT-flex50


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p y

Fuel rail made of one piece

WECS-9520 Cylinder-ElectronicUnit E95 boxes are fitted on theouter front side

SIB (E90) Box on free end


RT-flex Comp. & Systems Rail Unit


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p y

At engines with more than 7cylinders, the rail unit is split in twoparts.

Both rail-sections (forward/aft) forfuel-, servo- and control oil areconnected by high pressure pipes.=> Same pressure in the relatedrails of both halves.

WECS-9520 Cylinder-ElectronicUnit boxes (E95) are fitted on the

SIB Box (E90) on free end or in the

middle of the rail unit depending onthe number of cylinders




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p y


RT-flex Comp. & Systems Rail Unit RT-flex58/60


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RT-flex58T MK I RT-flex58T MK II




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RT-flex Comp. & Systems Rail Unit RT-flex82C/82T


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RT-flex Comp. & Systems Rail Unit RT-flex84/96


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RT-flex Comp. & Systems Rail Unit Main Parts


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Steam

ICUFuel oil rail:

The fuel rail contains high pressure fuel of ~ 600 - 800 bardelivered by the fuel pumps of the supply.

Fuel oil railFor each cylinder, there is an Injection Control Unit (ICU) .

The rail is heated by a trace heating piping system.

Servo oil rail: The servo oil rail contains fine filtered (6-micron) high pressureservo oil, ~ 80 - 190 bar, delivered by the servo oil pumps of the

, .a Valve Control Unit (VCU) .

Additional return/leakage piping: Servo oil railFuel ICU-leakage pipeCommon servo oil return pipe


RT-flex Comp. & Systems Rail Unit Piping RT-flex50


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Trace heatingICU

Fuel oil railFuel pressurerelief valve

Fuel overpressureregulating valve

Servo oil rail

VCU


ervo oreturn pipe



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Trace heatingFuel oil rail

ICU

Servo oil rail

VCU

Servo oilreturn pipe


RT-flex Comp. & Systems Rail Unit Piping RT-flex58/60, MK I


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The fuel rail contains high pressurefuel of ~ 600 -900 bar delivered bythe fuel um s of the su l unit

ICUsVCUs

during engine operation. The railpressure is regulated depending on

engine load. For each cylinder,ere s an n ec on on ro n(ICU) installed on the fuel rail. TheICUs are actuated by help of control oil ressure. WECS isFuel railactivating the ICUs for injectioncontrol. The rail is heated by a traceheating piping system.

Servo oil return pipe

Main bearing oil supply

Servo oil rail:

Control oil supply rail

filtered high pressure servo oil,

~ 80-190 bar, delivered by the servo oil pumps of the supply unit, dependingon engine load. For each cylinder there is a Valve Control Unit / exhaust


Control oil return rail valve actuator (VCU) installed on the servo oil rail. WECS is activating theVCUs for exhaust valve control.



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Additional piping in previousdesign:

ICU fuel drain pipe(constant orifice leakage

booster unit)

Fuel leakage drain (ICU

Trace heating

injection pipe leakage)Control oil supply rail tosupply actuating control oilto ICUsSeparate control oil returnrailMain bearing oil supply toVCU (refilling of drained oilthrough constant orifice in

Fuel leakage drain to overflow tank


ex aus va ve r ve



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Two electrically driven controloil pumps supply control oil withconstant pressure of 200 Bar to

SHD-valvearrangement

the control oil supply rail.

Overpressure regulating valve:Control oilSimilar function as the valveused for new design, but theSHD function is not included.

supp y ra

Control oilreturn rail

ue ra ne o over ow an

SHD-valve arrangement:e so eno va ve

(energised by Safety System)enables control air to the SHD-

servo that activates the SHD-valve itself to depressurize thefuel system (fuel drained tooverflow tank)


Overpressure regulating valve

RT-flex Comp. & Systems Rail Unit Piping RT-flex58/60, MK II


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The fuel rail contains high pressure fuel of ~ 600 -900 bardelivered by the fuel pumps of the supply unit duringengine operation. The rail pressure is regulated dependingon engine load.For each cylinder, there is an Injection Control Unit (ICU)installed on the fuel rail. The ICUs are actuated by help of

s

- .activating the ICUs for injection control.

The rail is heated by a trace heating piping system. Fuel rail

: The servo oil rail contains fine filtered (6-micron) high pressure servo oil, ~ 80-190 bar,delivered by the servo oil pumps of the supply

VCUs

unit, depending on engine load. For eachcylinder there is a Valve Control Unit / exhaustvalve actuator installed on the servo oil rail.

valve control.

The high pressure rails of new design are


made of single pipes. The ones of old design

rail of rail pipe sections.

RT-flex Comp. & Systems Rail Unit Piping RT-flex58/60, MK II


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Additional return/leakage piping:One fuel leakage pipe (back tooverflow tank)

Fuel leakage pipe

One common servo oil return pipe(back to crankcase)

Trace heating (steam or thermo oil) Safety valve

Servo oil return pipeue system overpressure vaves:

SHD and overpressure regulating valve.Opening pressure approx. 1050 bar forover ressure re ulation. The SHD-solenoid is

Trace heating

activated by Safety System to depressurize thefuel system (fuel drained to return pipe tobooster unit).

Safety valveOpening pressure 1250 bar. Fuel drained tooverflow tank.

SHD and overpressureregulating valve




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ue o ra :

The fuel rail contains high pressure fuel of ~ 600 -900 bar delivered by thefuel pumps of the supply unit during engine operation. The rail pressure isre ulated de endin on en ine load.

For each cylinder, there is an Injection Control Unit (ICU) installed onthe fuel rail. The ICUs are actuated by help of servo oil pressure

via hydraulic HP-hoses. WECS-9520 is activating the ICUsor n ec on con ro .


Servo oil rail: The servo oil rail contains fine filtered high

pressure servo oil, ~ 80-190 bar, delivered by theservo oil pumps of the supply unit, depending on

.Control Unit / exhaust valve actuator installed onthe servo oil rail. WECS-9520 is activating theVCUs for exhaust valve control.

The high pressure rails of new design are made of single pipes. The ones of old design rail of rail


.



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Servo Oil Returnfrom ICUs

ICU

SteamTracin

FuelLeakage

Fuel

Pipesue a

(1250 bar)

Servo OilLeakage fromVCUs & ICUs

SHD & PressureControl Valve

VCU

(1050 bar)re xtngu s ngPipe with Nozzles

Fuel from SU

Servo Oil Returnfrom VCUs

Servo OilRail

Wrtsil Land & Sea Academy Page 60 Chapter 20 Feb. 2010Servo Oil from SU



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Drive End

from SU Servo


from SU Fuel Pumps



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Depending on number of cylinders and engine maker,fuel- and servo rail pipes could made by two parts andassembled with Intermediate Piece

Intermediate Piece


Fuel Rail Fuel rail pipe has peanutshape bore.



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Drive End

VCU




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FuelLeakage

(230 bar)~

for Pulse Lubrication

Servo Oil Returnfrom VCUs

Servo OilLeakage

Servo Oil Rail


from Actuator Pipes

VCU

RT-flex Comp. & Systems Rail Unit Main Parts RT-flex84/96


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ICUsFuel oil rail: The fuel rail contains high pressure fuel of ~ 600 - 800 bar delivered by the fuel pumps of the supply.

For each cylinder, there is an Injection Control.


Servo oil rail:

Controloil rail

The servo oil rail contains fine filtered (6-micron) high

pressure servo oil, ~ 80 - 190 bar, delivered by the servooil pumps of the supply unit, depending on engine load.

Servo oil rail

VCUs

.

Control oil rail: The control oil rail contains 200 bar control oil (constant pressure) delivered by the controloil pumps.

Additional return/leakage piping:-


Common servo oil/control oil return pipe

RT-flex Comp. & Systems Rail Unit Piping RT-flex84/96


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Control oil

high pressurehoses

Trace heating

ICU and injection high pressure

(connected to leakage collector=> Alarm to AMS)

Control oil railervo o ra

Main bearing oil supply pipe forupper side of VCU (flex96C-B

Servo oil (and control oil)common return pipe


on y

RT-flex Comp. & Systems Rail Unit Piping


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own or - ex -




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-


RT-flex Comp. & Systems Fuel Rail Pipe

-


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The bore has a shapeof a peanut

The fuel rail pipe is made of one piece

Connecting piece


and ICU



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At each inlet, there are shut-off valves, in order to- .

Fuel-, servo- and control oil inlet to the rails are

cylinders)

For redundanc reasons there are for eachsystem two rising pipes connected to the two rail

unit halves

The cross-connection high pressure pipes enablea direct connection between each rail for

pressure equalizationif one HP pipe is broken, it can be shut-off onboth ends and the remaining one feeds bothrails




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Rail unit general drain piping. Possible leaks of fuel, oil and water are collected foreach rail => Alarm to Alarm System Rail Unit (FWD), General Leak.


e ea age s ra ne o e s u ge an .

RT-flex Comp. & Systems (fuel) Injection Control Unit (ICU)


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WECS-9520Servo (control) oil

supply 200 bar


RT-flex Comp. & Systems ICU RT-flex50


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RT-flex Comp. & Systems ICU RT-flex58/60


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RT-flex Comp. & Systems ICU RT-flex68


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RT-flex Comp. & Systems ICU RT-flex84/96


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RT-flex Comp. & Systems ICU, Working Principle


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Fuel quantity piston

ervo ra Fuel quantitysensor(Size 4:

Control rail)

Rail valves ue nozz es

Injection controlvalves

Fuel rail


RT-flex Comp. & Systems ICU, Working Principle


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Fuel quantity pistonFuel quantity pistonFuel quantity pistonFuel quantity pistonFuel quantity pistonFuel quantity piston

ervo ra Fuel quantitysensor






Rail valves ue nozz esRail valves ue nozz esRail valves ue nozz esRail valves ue nozz esRail valves ue nozz es

Rail valves ue nozz es return position







Fuel railFuel railFuel railFuel railFuel railFuel rail



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RT-flex Comp. & Systems ICU, Working Principle RT-flex82


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RT-flex Comp. & SystemsFuel uantit senso

ICU RT-flex50

ervo o s e:


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The rail valves control the oil flow to the control oilblock.Fuel quantity piston

Fuel s ide: The fuel control valves are actuated by pistons in thecontrol oil block. There is one valve for each injector.Fuel control

The main body of the ICU includes the injectionquantity piston.Fuel Quantity Sensor in a housing kept away fromServo oil side

.Servo oil and fuel oil side are entirely separated fromeach other. Nevertheless, leakages of both systemshave a common drain.

Servo oilreturn

Working principle:Each ICU is pre-controlled by 2 rail valves to open orFuel sidec ose e way or ue rom e ra o e n ec onnozzles.Fuel for each injection, necessary stroke is calculated

Rail valves


, ,for the next injection.

ervo osupply

RT-flex Comp. & SystemsFuel uantit sensor

ICU


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The rail valves control the oil flow to the control oil block.Fuel quantity pistonServo (control) oil side

The fuel control valves are actuated by pistons in thecontrol oil block. There is one valve for each injector.

The main bod of the ICU includes the in ection uantit

Servo oilreturn

piston.Fuel Quantity Sensor in a housing kept away from thehot block.

Rail valves

Fuel controlvalves

Control- and fuel oil side are entirely separated from eachother. Nevertheless, leakages of both systems have acommon drain.

Working principle:Each ICU is pre-controlled by 3 rail valves to open or

close the way for fuel from the rail to the injectionnozzles.Fuel for each injection, necessary stroke is calculatedFuel side

Servo oilsupply


, ,the next injection.

RT-flex Comp. & Systems ICU Cross-Section


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steel filter



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RT-flex Comp. & Systems ICU Cross-Section RT-flex82


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To InjectorsQuantity PistonQuantity Sensor

From Fuel Rail


RT-flex Comp. & Systems ICU Cross-Section RT-flex82

Injection Control Valves


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Distance Piece


Rail Valveson ro s ons

RT-flex Comp. & Systems ICU, new leak drain RT-flex96C

l


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New piping layout separatesleak drain from injection pipesand from ICU internals.

Inspection plug for visualcheck of leak.


RT-flex Comp. & Systems Fuel Nozzle (not MK I, 82)


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Fuel nozzle withventing spiral(not valid for MK I

Opening pressure 375 bar

Wrtsil Land & Sea Academy Page 89 Chapter 20 Feb. 2010 MM, chapter 2722

RT-flex Comp. & Systems Fuel Nozzle RT-flex82

from ICU


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Opening Pressure:375 10 bar

Fuel ReturnPassage

Shim RingsOpening Pressure is adjusted by Adjusting of ShimRings thickness


MM, chapter 2722

RT-flex Comp. & Systems (exhaust) Valve Control Unit (VCU)


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RT-flex Comp. & Systems VCU (general working principle)

The valve control unit is pre-controlled by the rail valve .

k l h l l l


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At a certain crank angle, it gets an exhaust valve open impulse signal- .

Slide Rod and moves it up. Thus, servo oil flow to the VCU-cylinder isenabled. Via bores in the VCU-piston , oil flows into the lower side of the piston and moves it towards the upper end. the exhaust valve opens

At another calculated angle, WECS-9520 transmits an exhaustvalve close signal to the rail valve. The Slide Rod movesdown by mechanical spring, releasing the oil from theVCU-piston underside allowing the oil volume in theexhaust valve to return to the VCU. The servo oil

servo oil return pipe. the exhaust valve is closing

Due to certain control bores, the VCU- piston hasa progressive movement. Means, it starts to movefast and slows down, as it gets closer to the end stop.


RT-flex Comp. & Systems VCU, Monobloc RT-flex50, MKII, 68, 82, 84T


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RT-flex Comp. & Systems VCU, 3-Block RT-flex58T/60C (MKI), 96


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RT-flex Comp. & Systems VCU, Working Principle


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*

Oil supply * )

Servo rail

external from lube oil

os ton senso


RT-flex Comp. & Systems VCU, Working Principle


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Oil supply

Oil supply

Oil supply

Oil supply

Oil supply

Oil supply

Oil supply

Oil supply

Servo railServo railServo railServo railServo railServo railServo railServo rail

os ton sensoos ton sensoos ton sensoos ton sensoos ton sensoos ton sensoos ton sensoos ton senso


RT-flex Comp. & Systems VCU, Working Principle RT-flex82


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e ro s on x aus va ve

Servo rail

Position senso

pr ng a r


RT-flex Comp. & Systems VCU, Working Principle RT-flex82


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e ro s on x aus va vee ro s on x aus va vee ro s on x aus va vee ro s on x aus va vee ro s on x aus va vee ro s on x aus va vee ro s on x aus va vee ro s on x aus va ve

Servo railServo railServo railServo railServo railServo railServo railServo rail

Position sensoPosition sensoPosition sensoPosition sensoPosition sensoPosition sensoPosition sensoPosition senso

pr ng a rpr ng a rpr ng a rpr ng a rpr ng a rpr ng a rpr ng a rpr ng a r


RT-flex Comp. & Systems VCU RT-flex58T/60C (MKI), 96

The servo oil supply from the servo oil rail toTo exhaustvalve


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pp ythe 3/2 way valve is done via connecting

To exhaust valve

element. The 3/2 way valve is pre-controlled bya rail valve (same type as for ICU).

Rail valve

of ~2-3 bar to dampen pressure peaks.

To the upper part of the VCU/actuator pipe,

Main bearing oilsupply

there is a main bearing oil inlet via a non-returnvalve, in order to fill up the oil losses throughthe orifice in the exhaust valve drive.

VCU c linder

Connecting

and piston

Servo oil returne emen


RT-flex Comp. & Systems VCU RT-flex58T/60C (MKI), 96


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New stainlesssteel filter


RT-flex Comp. & Systems Valve Control Unit (VCU) RT-flex82

to Exhaust Valve


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to Exhaust Valve

Servo OilLeakage from

c ua or p peSlide Rod(block inside)

VCU Piston

(block inside)

Filter

Rail ValveServo Oilto ICU


RT-flex Comp. & Systems VCU RT-flex50, MK II , 68, 82, 84T-D

Rail Valve Slide Rod To Exhaust valve


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.

In order to refill the intended oil loss through theconstant orifice in the exhaust valve drive upper

,part of the VCU Piston (to actuator pipe).

To ICU

Servo Oil


Piston Filter insert Internal Orifice plug inside

RT-flex Comp. & Systems Exhaust Valve Drive

Main differences to a conventionalRTA-valve drive:

Damper Orifice


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RTA-valve drive:

The exhaust valve is actuated by adouble piston drive, in order to save oil

exhaust valveactuator pipe Thrust piece

Two redundant exhaust valve strokesensors for monitoring

Double pistondrive

ne measur ng cone or stro e sensors

Air spring piston runs directly in thehousing.

Measuring cone

Two exhaust valvestroke sensors

The disc spring package is dampeningopening stroke in case of low air springpressure

Air spring piston

Disc spring

Exhaust valve spindle


RT-flex Comp. & Systems Exhaust Valve Drive


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RT-flex Comp. & Systems Exhaust Valve Drive RT-flex82

Orifice

Oil Drain Stroke

Sensor


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Spring Air

w t r ce


RT-flex Comp. & Systems Rail Valves


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RT-flex Comp. & Systems Crank Angle Sensor (CA)

The crank angle sensors are located on the free end of the crankshaft (or Geislinger Damper).


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The crank angle signal is absolutely indispensablefor engine operation.

At least one of the sensors must be working. If one fails, WECS-9520 can detect the failure andwill keep working with the healthy signal

. ,engine will stop without delay.

There is no emergency operationpossible without at least one CA

sensor


RT-flex Comp. & Systems CA-Sensor

They are separated from the crankshaft by a special coupling. They create an exact digital signal of theactual crankshaft position (0.360) The CA sensors have a resolution of 0.1


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The spring loaded coupling absorbs all longitudinal and axial movement of the crankshaft. It drives a shaftwhich is supported by two ball bearings. The bearings are oil lubricated. From the shaft a toothed beltdrives each sensor.

Shielded BUS cables transmit the signals to theWECS-9520 control.

-

CA-Sensor, com lete with holder and cable.




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MM, chapter 9223


Connection unit CA Sensors


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RT-flex Comp. & Systems TDC Pick-up

TDC Pick-up-


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sensing Top Dead Centre of cylinder #1

The sensor si nal tooth is used b WECS-9520 to compare the twoCAS signals with the TDC sensorsignal to detect faulty / drifted crankang e sensors, amage r vesand twisted crankshafts.

The other pick up sensors are used.

TDC #1 tooth at the flywheel


RT-flex Comp. & Systems TDC Pick-up RT-flex82

The TDC pick-up at the flywheel is


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cylinder #1

The sensor signal tooth is used byWECS-9520 to com are the twoCAS signals with the TDC sensorsignal to detect faulty / drifted crankangle sensors, damaged CA drivesan ws e cran s a s.

The other pick up sensors are usedfor Propulsion Control System.

TDC Pick Up TDC #1 tooth at


RT-flex Comp. & Systems Local Control Stand RT-flex50


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RT-flex Comp. & Systems Local Control Stand


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RT-flex Comp. & Systems Air system

Air is used for:


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Starting of engine

(Oil mist detector)

Flushin of automatic filter for servoand control oil

@ (OMD)


RT-flex Comp. & Systems Air supply

From starting air bottles (30 bar)

From control air

To air springs To automatic mainstarting valve

throu h turnin ear

supply (7-9 bar)


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supply (7 9 bar)

@ (OMD)@ (SHD valve)


on ro a r as o e a us eslightly higher than back-up air (19HA)

RT-flex Comp. & Systems Control air supply unit


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RT-flex Comp. & Systems Control air supply unit RT-flex50


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RT-flex Comp. & Systems Air system RT-flex50

Air is used for:


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Starting of engine

(Oil mist detector)

Flushin of automatic filter for servoand control oil


RT-flex Comp. & Systems Air supply RT-flex50

From control airsupply (7-9 bar) To air springsand automatic

main starting


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valve throughturning gear


RT-flex Comp. & Systems Main starting valve


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RT-flex Comp. & Systems Starting air


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RT-flex Comp. & Systems Starting Pilot Valve


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20 rt flex comp syst

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