RT-flex Control Elements

RT-flex Training

Function of the different

Hydraulic- and Pneumatic
Components

Chapter 30

© Wärtsilä Land & Sea Academy Page 1 Chapter 30 26-Apr-07

RT-flex Control Elements Overview

Main Functions
Exhaust Valve Control Injection Control Starting Valve Control

Auxiliary Functions
Fuel pressure control
Servo oil pressure control

Control oil pumps control

Valve stroke measurement
ICU stroke measurement

Crank angle detection

© Wärtsilä Land & Sea Academy Page 2 Chapter 30 26-Apr-07

RT-flex Control Elements Injection Control Unit (ICU)

The ICU controls the timing and volume

of the injection.
Each ICU has 3 (or 2) “rail valves” to pre-
control its own “injection control valve”.
The injection control valves control the
movement of the “fuel quantity piston”.

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RT-flex Control Elements ICU

WECS-9520
control

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RT-flex Control Elements ICU

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RT-flex Control Elements ICU

Fuel quantity piston

Servo rail
Fuel quantity
(Size 4: sensor
Control rail)
Fuel nozzles
Rail valves

Injection control
valves

Fuel rail

© Wärtsilä Land & Sea Academy Page 6 Chapter 30 26-Apr-07

RT-flex Control Elements ICU, new leak drain (96C-B)

New piping layout separates leak

drain from injection pipes and from
ICU internals.

Inspection plug for visual check of

leak.

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RT-flex Control Elements (exhaust) Valve Control Unit (VCU)

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RT-flex Control Elements VCU

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RT-flex Control Elements VCU (general working principle)
The valve control unit is pre-controlled by the rail valve.
At a certain crankangle, it gets an „exhaust valve open“
impulse signal from WECS. Servo oil flows via rail valve Actuator pipe with
to the lower side of the 3/2 way valve spindle and moves main bearing oil
it up. Thus, servo oil flow to the VCU-cylinder is enabled.
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
„exhaust valve close“ signal to the rail valve. The 3/2
way valve spindle moves down, releasing the oil from
the VCU-piston underside allowing the oil volume in the
exhaust valve to return to the VCU. The servo oil
underneath the VCU piston is drained to the servo oil
return pipe. Rail valve

the exhaust valve is closing
Due to certain control bores or chamfers, the VCU- 3/2 way valve
spindle
piston has a progressive movement. Means, it starts to
move fast and slows down, as it gets closer to the end
stop. The losses of servo oil through the orifice on the The servo oil return pipe has a back
exhaust valve side is compensated in the VCU with VCU piston pressure of ~2-3 bar, in order to
servo- or main bearing oil. dampen pressure peaks.

© Wärtsilä Land & Sea Academy Page 11 Chapter 30 26-Apr-07

RT-flex Control Elements VCU (60C, MKI)
3/2 way valve To exhaust valve drive

The servo oil supply from the servo oil rail is

done via connecting element.

Main bearing oil To compensate the intended oil loss through the
supply, (non return constant orifice in the exhaust valve drive upper
valve at inlet) housing, there is a main bearing oil inlet via a
non-return valve.
Rail valve

VCU cylinder

Servo oil return/

Filter insert outlet

Connecting element

© Wärtsilä Land & Sea Academy Page 12 Chapter 30 26-Apr-07

RT-flex Control Elements VCU (60C, MKII)
Rail Valve

The VCU sits directly on the servo rail.

To exhaust
valve drive 3/2 way valve In order to refill the intended oil loss through
the constant orifice in the exhaust valve drive
upper housing, there is an internal orifice to
the upper part of the VCU/actuator pipe.

Servo oil return

VCU piston

HP-hoses to/
Servo oil supply from ICU

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RT-flex Control Elements VCU

Rail valve Slide rod Piston Exhaust valve

Oil supply
Servo rail (internal from servo rail
or external from lube oil)

Position sensor

Spring air

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RT-flex Control Elements Automatic Filter

Servo oil and control oil is fine filtered before it enters the pumps and hydraulics. The automatic filter
has cartridges of nominal 6 µm. There is an bypass filter of 36 µm mesh size.
The reason for filtering is to increase the lifetime and safety margin of all hydraulic components.

Control box with indications

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RT-flex Control Elements 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 for normal
use.
In the filter control box the back flushing is initiated either by time or differential pressure. Flushing
cycles are counted. Failure messages are generated if necessary (Overcurrent, differential pressure
high etc…)
Inside the box there is a switch with positions "Operation" and "Adjust". After switching to "Adjust" some
parameters become adjustable. Adjustable parameters are e.g. the flushing interval.

© Wärtsilä Land & Sea Academy Page 17 Chapter 30 26-Apr-07

RT-flex Control Elements Air system

Air is used for:

 Actuation of automatic start valve
 Starting of engine
 Spring air supply
 Oil mist detector
 Flushing of automatic filter for servo
and control oil

(OMD)

(SHD valve)

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RT-flex Control Elements Control air supply unit

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RT-flex Control Elements Air supply

From starting air bottles (30 bar)

To air springs To automatic main
starting valve
From control air
through turning gear
supply (7-9 bar)

(OMD)

(SHD valve)

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RT-flex Control Elements Pneumatic starting interlock

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RT-flex Control Elements Main starting valve

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RT-flex Control Elements Starting air

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