Professional Documents
Culture Documents
V. Electrical Diagrams
Version 1.0
Objective
Have more appreciation of the electrical system of the Rt-flex by proper interpretation of drawings and
symbols.
Understand the working principles and operational functions of the symbols in the diagrams and locate
these in the actual.
RT-Flex68 / RLO5.0 ver1.0 © Copyright 2009, Wärtsilä Land and Sea Academy Inc. Page 2 of 41
Power Supply Box
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E-90
RT-Flex68 / RLO5.0 ver1.0 © Copyright 2009, Wärtsilä Land and Sea Academy Inc. Page 7 of 41
9 CYLINDER
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RT-FLEX 50
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RT-Flex68 / RLO5.0 ver1.0 © Copyright 2009, Wärtsilä Land and Sea Academy Inc. Page 10 of 41
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E-95
FCM MODULE
RT-Flex68 / RLO5.0 ver1.0 © Copyright 2009, Wärtsilä Land and Sea Academy Inc. Page 12 of 41
E95.01-E95.08
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RT-Flex68 / RLO5.0 ver1.0 © Copyright 2009, Wärtsilä Land and Sea Academy Inc. Page 14 of 41
E95.01
E95.02
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E95.03
E95-04
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E95.05
E95.06
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E95.07
E95.08
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5 CYLINDER
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6 CYLINDER
7 CYLINDER
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8 CYLINDER
E95.01
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E95.02
E95.03
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E95.04
E95.05
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WIRING & FAILURES
Wiring
Loose or broken cables can stop a cylinder or simply cause a sensor alarm.
Defects on the wiring can not be detected easily and the following points have to be observed:
o Wires have to be laid in a cable duct, secured with cable retainers to avoid faults by vibrations
o Wires must not be criss-crossed but running in parallel, not scouring on other elements
For wirings marked as shielded in the diagrams, shielded cable MUST be used. The shield must be
connected to the mass only on the end defined in the diagram
“L” (low-power/sensitive) and “H” (high-power) wires have to keep separate and always guided
separately with a distance of about 25 cm to avoid interference to signals.
Bus cabling:
Check regularly all terminal bars for loose connections.
For any of the bus systems, only special 120W bus cables must be used! (Bus- or Data cables with 110W to
130W)
Bus cables MUST NEVER be connected as “star-connection” (parallel) but only in serial! Not even for an
emergency repair!
RT-Flex68 / RLO5.0 ver1.0 © Copyright 2009, Wärtsilä Land and Sea Academy Inc. Page 24 of 41
Troubleshooting WECS
Mostly malfunctions appear because of wrong from or to the control system, caused by:
loose cable connections, sensor targets or links
badly crimped cable-end sockets
clogged inlet ports at pressure-sensors, transmitters and switches
sensor exposed to excessive vibrations, heat, dirt, moisture or abnormal wear
earth faults
short circuits
broken wires
noisy signals (EMC)
wrong sensor type
wrong parameters or scaling of sensors
false connections
low power supply
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Injection quantity feedback signals:
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If a disturbed feedback signal is within the range of 4-20 mA, the WECS can not recognize the
erratic signal condition. For such a failure the Injection Curve in the Service menu is used for
investigating the signal shape and to determine, if the sensor is working correctly:
Spikes like these in the signal shape indicate accelerations of the fuel quantity sensor beyond any
physical measures, its clear evidence for a Sensor failure.
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If the feedback signal deteriorates like this, there is no doubt that a damaged fuel qty. sensor is causing
wrong and unstable injection timing of the respective cylinder.
Alarm Monitoring
5 different groups of WECS failures are transmitted via CAN/Modbus to the alarm monitoring system:
• Passive Failures.
Failures of redundant sensors, busses or components:
• Common Failures;
Cylinder unit failures without redundancy or common system failures that do not cause
any speed reduction;
• Cylinder Failures
Any cylinder unit failures that cause a slowdown via AMS;
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Passive Failures
failure, check the CAN S-Bus wiring in all E95 boxes and
FCM n CAN S1/2
Comm. FAIL #n
terminating resistors.
Active, if crank angle sensor is failing or FCM-20 # (last and last-1)
Crank Angle #1(2) Failure
are switched off.
If failure appears on all active modules, check CA-sensor 1(2) and
FCM n SSI CA1/2
replace if necessary. Else check SSI-bus terminating resistors on
X22 /23 in E95.01.
If failure on single modules, check plugs X22 and X23 for proper
wire connections. Replace module if required.
Any FCM-20 Module, Cylinder remains in operation, but after any new restarting
Cyl. Identification lost (powering up) of the FCM-20 module the cylinder is cut-off.
FCM n ID Check address wiring in corresponding E95 box on plug X25.
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Common Failures
Servo Oil pressure, meas. Fail. Diff. Compare both servo-oil rail pressure indications, if possible
hi change engine load through a wider range and verify which
sensor does not follow up linearly to the changing servo oil
FCM 1+2 AI2 2x pressure.
Check cabling on X27 and “Analog In” LEDs on FCM-20 #1 and 2.
Replace sensor if necessary.
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Alarm Card Indication Countermeasures
Servo Oil Pressure hi DYNEX pump: Controller valve on pump not adjusted (after
overhaul). Wrong parameters set in flexView software.
FCM 1+2 AI2 3x BOSCH pumps: Check electronic controller card indications for
troubleshooting.
Servo Oil Pressure Oil pressure after automatic filter OK?
Check signal and cables to DYNEX/Bosch pumps OK?
Check BOSCH controller card indications for troubleshooting.
FCM 1+2 AI2 4x Safety valve 4.23 open? Ctrl oil supply to Bosch pumps OK?
Drain from controller block open or inlet valves for servo oil rail
closed?
Can appear shortly during engine start, if more than one
pump/control fails or switched off.
Can also indicate sever failure in hydr. exhaust control parts.
If a servo oil pump is much cooler than the others while engine is
running, carrier sleeve on drive shaft is broken.
Servo Oil pump #n, No flow Pipe crack? Flow sensor failing (Dynex pumps only)
Check local swash plate indication (Bosch Rexroth only)
FCM 3,4…8 PWM 2x Refer also to co-alarms for troubleshooting( e.g. servo oil
pressure
low).
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Alarm Card Indication Countermeasures
Fuel Rail Pressure 1+2, Meas fail Check fuel rail pressure transmitter 1 and 2,
Check cabling on X25 and “Analog In” LEDs on FCM-20 #3 and 4.
FCM 3+4 AI1 1x Voltage supply 24V available on plugs?
Fuel Rail Pressure, Meas. Fail diff Compare both fuel rail pressure indications, if possible change
Hi engine load to range, where fuel rail pressure varies with load
(e.g. 15-20% or 70-80%) and verify which sensor does not follow
FCM 3+4 AI1 2x up linearly.
Check cabling on X25 and “Analog In” LEDs on FCM-20 #3 and 4.
Replace sensor if necessary.
Fuel Rail pressure Hi Check fuel pressure regulating linkage for free movement.
Check if fuel pressure actuators (Woodward) are switched on and
FCM 3+4 AI1 3x working.
Assembly mistake of fuel pump? (After overhaul).
Check for fuel actuator alarms in alarm monitoring system.
Can appear during short nervous manoeuvring, if engine is
repeatedly started and stopped without having any fuel release
in between.
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Alarm Card Indication Countermeasures
TDC signal, fail Check TDC-Pickup for correct cabling and correct distance to
flywheel tooth . Measure voltage supply and signal. Replace
FCM 5 BI1 1x sensor if necessary.
Check wiring in E95.05 on X27 and LED indication on FCM-20 #5.
Crank Angle, TDC lo shift CA sensor drive shaft or belts shifted?
TDC offset wrongly adjusted?
FCM 5 BI1 2x CA1 lo shift Possibility of shifted crankshaft?
FCM 5 BI1 4x CA2 lo shift
Crank Angle, TDC hi shift CA sensor drive shaft or belts shifted?
TDC offset wrongly adjusted?
FCM 5 BI1 3x CA1 hi shift Possibility of shifted crankshaft?
FCM 5 BI1 5x CA2 hi shift
Cylinder Failures
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Alarm Card Indication Countermeasures
Injection #n Cut-off Manual (user-) cut-off or automatic cut-off indication
Refer to co-alarms in case of automatic cut-off.
No LED code
Control Oil Pressure Very Low At least 1 pump running? (2nd should start in case of low
pressure)
Main oil supply and pressure after automatic filter OK?
FCM 5 AI1 5x Leakage or shut-off cock for oil drain open?
El. power to pump drives ok?
Servo Oil Pressure Very Low Oil pressure after automatic filter OK?
Control signal and cables to DYNEX / Bosch pumps OK?
FCM 1+2 AI2 5x Check BOSCH controller card indications for troubleshooting.
Safety valve 4.23 open? Ctrl oil supply to Bosch pumps OK?
Drain from collector block open or inlet valves for servo oil rail
closed?
Can appear shortly during engine start, if more than one pump /
control fails or switched off. Can also indicate severe failure in
hydr. exhaust control parts.
If a servo oil pump is much cooler than the others while engine is
running, carrier sleeve on drive shaft is broken.
RT-Flex68 / RLO5.0 ver1.0 © Copyright 2009, Wärtsilä Land and Sea Academy Inc. Page 34 of 41
Critical Failures
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BUS Cabling
Terminator resistors
At each end of the Bus cable a terminator resistant of 120W MUST be installed to avoid signal
reflection.
RT-Flex68 / RLO5.0 ver1.0 © Copyright 2009, Wärtsilä Land and Sea Academy Inc. Page 36 of 41
FCM – 20 Module
RT-Flex68 / RLO5.0 ver1.0 © Copyright 2009, Wärtsilä Land and Sea Academy Inc. Page 37 of 41
FCM-20 Hardware I/O Low
• MODbus Traffic
24Vdc
E85 24Vdc out
Exhaust Valve
Position Feedback
Power 4-20 mA
Supply
Fuel Quantity
Feedback
4-20 mA
RT-Flex68 / RLO5.0 ver1.0 © Copyright 2009, Wärtsilä Land and Sea Academy Inc. Page 38 of 41
WECS-9520 Functional Design
The WECS9520 system is built with a single multifunctional electronic module FCM-20 = Flex Control
Module 20
E95.02
E95.01
Box Box
RT-Flex68 / RLO5.0 ver1.0 © Copyright 2009, Wärtsilä Land and Sea Academy Inc. Page 39 of 41
Standard External System
ModBus #4
#2
flex Engine
WECS-
CANopen Module Bus #4
9520 CANopen System Bus
FCM -20
FCM -20
FCM -20
FCM -20
FCM -20
FCM -20
FCM -20
CANopen
online
spare
Cyl. 2
Cyl. 3
Cyl. 4
Cyl. 5
Cyl. 6
Cyl. 1
Starting Air
VCU Crank-Angle CR Pumps CR Pumps Fuel Pressure
3x ICU SSI Bus Fuel Pressure Fuel Pressure Actuator For engines with more
Actuator Actuator than 6 cylinders
RT-flex Eng
Servo oil Servo oil Servo oil Servo oil
CA Pump Pump Pump Pump
Local Manual Panel
RT-Flex68 / RLO5.0 ver1.0 © Copyright 2009, Wärtsilä Land and Sea Academy Inc. Page 40 of 41
KM AC20 + DC20 System Version
FCM-20
FCM-20
FCM-20
FCM-20
FCM-20
CANopen
CANopen
online
spare
Cyl. 3
Cyl. 4
Cyl. 5
Cyl. 6
Cyl. 1
Cyl. 2
Starting Air
VCU Crank-Angle CR Pumps CR Pumps Fuel Pressure
3x ICU SSI Bus Fuel Pressure Fuel Pressure Actuator For engines with more
Actuator Actuator than 6 cylinders
RT-flex Eng
Servo oil Servo oil Servo oil Servo oil
CA Pump Pump Pump Pump
Local Manual
Panel
RT-Flex68 / RLO5.0 ver1.0 © Copyright 2009, Wärtsilä Land and Sea Academy Inc. Page 41 of 41