RTflex Engines

Service Bulletin

RT-flex1

Technical Information to all Owners / Operators

of Sulzer RT-flex Engines

31.08.2005

28.96.71.40 Printed in Switzerland

Practical Tips Based on

Service Experience

Wrtsil Switzerland Ltd

Wrtsil Schweiz AG
Wrtsil Suisse SA

PO Box 414
CH-8401 Winterthur
Switzerland

Contents:

Page

1.

Introduction

2.

Mechanical Components

3.

Wrtsil Engine Control System

(WECS)

4.

General Information

5.

Service Bulletin Published for

5
Large Bore RTflex Type Engines

Tel. +41 52 262 49 22

Fax +41 52 212 49 17
Email: mailch@wartsila.com

RTflex Engines

1.

INTRODUCTION

This Bulletin provides the latest information based on experience acquired from RTflex
engines in operation. It is complementary to the engine manuals and illustrates some topics in
further detail for maintenance and trouble shooting.
This Service Bulletin is valid for following Sulzer RTflex engines:
RTflex58TB
RTflex60C
RTflex96C
The indicated numbers e.g. (3.03) are related to the engine control diagrams as printed in the
Operating Manual.

2.

MECHANICAL COMPONENTS

2.1.

Alarms from Fuel Quantity Sensor (3.03)

Alarms such as Injection quantity piston, stuck in max. position", Injection quantity piston, no
return" have often been misinterpreted as seizure of the fuel quantity piston in the injection
control unit (ICU). In several cases complete ICUs were exchanged and sent to Wrtsil for
investigation where it would not been necessary.
To avoid unnecessary exchange work on board, transportation costs and then investigation
effort at our side, please consider the following:

Alarms saying Stuck", are in most cases not caused by really mechanically stuck or seized
quantity piston. In fact this case can almost be excluded. Exchanging the complete ICU is
not the first reaction that is appropriate.

A quantity piston reported Stuck" is normally hydraulically kept in a position by fuel. The
reasons are: either stuck rail valve (3.76), damaged Valve Driver Module (VDM), slack
cable plug on rail valve, faulty stroke sensor (3.03), slack cable plug to stroke sensor,
aluminium sliding tube of stroke sensor came loose, or seldom Cylinder Controller Module
(CCM).

Trouble shooting hints:

- Are cables tight to all rail valves and to the fuel quantity sensor?
- If WECS9500 is applied - Set a trend monitoring on time" inject and return of all
three valves. Record it over a few hours period. Replace valve showing long times (above
3.0ms). In case, after rail valve replacement, the on time" is still high replace the VDM
and / or CCM.
- Fuel quantity sensor: Check cable and plug / socket connection to the sensor. Check
either that the measuring sleeve is properly fitted (tight) to the quantity piston stem, or
the sleeve for eccentricity. If any of these checks shows a problem, replace the sensor.
- To check free movement of the quantity piston stem the fuel rail must be totally pressure
free (press Emergency Stop Button). Fuel booster pumps must also be stopped. After
removing the stroke sensor and its housing, the piston can be moved and turned by hand.
Just a bit of fuel pressure in the rail makes it impossible to move the piston, which is
normal.
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Service Bulletin RTflex1

RTflex Engines

2.2. Wear Recognition on the Injection Control Unit (3.02)

Heavy abrasive contamination of the fuel can lead to wear at the control edges in the ICU. This
can have a negative impact on the injection pattern.
On engines equipped with WECS9500 it is a good advice to look at the so called "injection
curves" regularly. They can be drawn in flexView as follows:
Switch access level to Service. Password is flexView
Click on View, select Injection curve
Select Cylinder number, One cycle, Scan
The drawn curve represents the signal of the fuel quantity sensor (3.03) during one injection
stroke. From its shape it can easily be distinguished if there is a critical wear apparent or not
(Fig. 1).

Worn condition: Bump" between

horizontal line and rising line.

Good condition: clear bend between

horizontal line and rising line.
Fig. 1

Examples of Injection Curves

Explanation
Heavy contamination of the fuel with abrasives (catalytic fines, etc.) can damage the control
valves of the three injection channels inside the ICU. This together with an automatic timing
adjustment in the WECS (Wrtsil Engine Control System) leads to retarded beginning of
injection. This can be several degrees, depending on the intensity of the wear.
Retarded injection lowers the firing pressure and raises the cylinder temperature. This
condition must be rectified as soon as possible, and the ICU needs to be overhauled. The fuel
separation system must be returned to normal efficiency with the highest priority.
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Service Bulletin RTflex1

RTflex Engines

2.3.

Checks on the Crank Angle Sensors (1.01)

To ensure troublefree operation of these important sensors we recommend carrying out some
regular checks. These are additional to the instructions stated in the Maintenance Manual.

Axial clearance on sensor

At every 3,000 operating hours check whether there is any axial freedom of movement
between the sensor wheel and the housing.
If there is freedom of movement, the sensor needs to be exchanged immediately. Such
freedom can occur if the belt tension was set too high.

Belt tension
When exchanging sensors the belt tension must be set according to instructions given in the
Maintenance Manual, page 92231/1A1, chapter 3. The spring balance must be used and
the tension of 4.5 kg must not be exceeded. Excessively tensioned belts lead to
selfdestruction of the sensor.

Oil flow
An easy way to ensure that there is an oil flow to the internal ball bearings is to touch the
supply pipe leading to the housing. If it does not feel warm then there is the risk that the fine
inlet orifice in the housing is blocked. It must be freed as soon as possible to avoid
dryrunning of the ball bearings.

Numbering
To avoid misunderstanding in the case of sensor alarm we advise you to check once if the
sensors are plugged in to the correct sockets in box E96. Unplugging the cable of sensor 1
(sensor on fuel side, port side) must activate an alarm of sensor 1.
If necessary apply numbers to plugs and sockets in box E96.

2.4.

Fuel Overpressure Safety Valve (3.52)

From experience we learnt that this valve is often not sealing well after it has opened. Either it
keeps leaking a little or it leaks so much that the fuel rail pressure cannot be built up.
Basically this safety valve (3.52) should hardly ever have to open. In some isolated cases of fuel
high pressure peaks it appeared that the fuel pressure regulating valve (3.06) opens too slowly
and thereby causes the safety valve to open.
For the time being this means that if, after a pressure peak situation, the safety valve leaks it
must be replaced by a new one.
2.5.

Cylinder Cutoff

In case the injection on one cylinder has to be cut off make sure injection cannot occur and
therefore it is advisable to do it redundantly:

Use function Inj. cutoff" in flexView, page USER (For WECS9520 this function is in the
RCS panel)
Unplug the cables from the injection rail valves 3.76 on the concerned unit

This increases safety against unwanted injections.

2.6.

Fuel Pumps - Regulating Rack

Check every 1,500 operating hours for a free movement of the regulating rack on all fuel pumps.
Pushing or pulling the fork lever must make the rack move for the complete stroke. Only the
torsional spring must restrict the movement.
The rack must be lubricated every 1,500 operating hours.
3/5

Service Bulletin RTflex1

RTflex Engines

3.

WRTSIL ENGINE CONTROL SYSTEM (WECS)

3.1.

Welding

Note that electric arc welding on the engine with WECS powered can be harmful to the
electronics. We advice using portable welding equipment and connect the earth cable close to
the actual welding point to avoid sneaking currents. Welding cables should not run close or
parallel to cable trays.
If electric arc welding must be done close to WECS components then it is safe to do so only after
first switching off the WECS, therefore use the breakers in the terminal boxes E85.
3.2.

WECS9500 Hard Disk Failure in WECSAssistant - Disk Overflow

The computer used in the WECSAssistant is basically a standard industrial computer. It

contains two hard disks in RAID configuration. They store the flexView application, the
WECS9500 backup copy, the history and alarm databases and the print screens.
Hard disks can unfortunately fail. This does not puts the engine operation in any danger but
flexView functions become affected or nonfunctional. Hard disk failures can be announced by
different popup windows on the screen. They typically contain keywords like sync fail", HD",
backup". The computer may hang itself up. In such a case, try to restart the computer in a
regular way. It will normally keep running with the remaining good hard disk.
In such cases it is advisable to replace the computer. Replacement of only the hard disks is
possible, but should only be done by skilled computer personnel.
3.2.1. Disk Overflow
The flexView stores a great deal of historical data to the hard disk. This can, after some time,
lead to an overflow" message on the flexView screen. If this happens, space on the hard disk
can be freed easily by following procedure:
- Minimize flexView window
- Open MS Windows Explorer
- Go to path c:\program files\flexview\<plant>\..
In this folder there is a long list of files of type <plant>000x.h5
They can be all deleted except the last three files. Delete them by using the keys Shift" and
Del". In the subfolder flexzip all previously delete files are stored still but in zipped version, so
no data are lost.
4.

GENERAL INFORMATION

4.1.

Technical Advice

To assure an efficient handling of all questions and claims please use the correct contacts.

For all warranty claims (failed parts of RTflex technology) contact your warranty agent at
Wrtsil Switzerland.

For all commercial orders contact the parts sales agent of your local Wrtsil Network
Company or representative.

For general technical advice on RTflex engines use the following email address:
customersupport.ch@wartsila.com or fax no. +41 52 262 07 31

By observing this structure we can assure a quick and most efficient handling of your requests.
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Service Bulletin RTflex1

RTflex Engines

4.2.

Returning of Defective Parts for Investigation

If parts, especially RTflex components, are found defective, Wrtsil Switzerland has in some
cases an interest to receive them for further investigation to gain feedback.
To handle this in a correct way please note following:
First check with Wrtsil Switzerland (your contact according 4.1) whether there is an interest
to investigate the parts in question. If interest is confirmed please follow the instructions given
by your contact person.
For each part a Return Parts Data Sheet" needs to be completed. If returning WECSmodules
we ask you to fill in additionally the Data Sheet for WECSModules".
Enclosures:

- Return Parts Data Sheet (1 page)

- Data Sheet for WECSModules (1 page)

This Service Bulletin should be kept in a separate file in the engine office.
NOTE:
It is entirely within the responsibility of the shipowner or ship operator to instruct their personnel in
charge to follow and implement the recommendations contained herein.
Wrtsil Switzerland Ltd has issued this Service Bulletin to the best of their knowledge and ability.
However, Wrtsil Switzerland Ltd can not assume any liability for any and all information contained
in this or any other Service Bulletin.
Changes of any nature to the form and / or to the content of this or any other Service Bulletin as
published by Wrtsil Switzerland Ltd, are not permitted.
5.

SERVICE BULLETINS PUBLISHED FOR LARGE BORE RTflex - TYPE ENGINES

We have so far published the following Service Bulletins which are valid for Large Bore RTflex -Type Engines :
RTA-14.1 dated 23.08.2002 System Oil Care and Maintenance
RTA-15
dated 10.02.94
Elastic Studs on RTAType Engines
RTA-18.2 dated 14.06.2002 Runningin of Cylinder Liners and Piston Rings
RTA-24.2 dated 18.05.99
VTR..4 Turbochargers After Sales Service Information issued by ABB
RTA-33.1 dated 05.12.2003 Crank Pin Bearing Shell
RTA-38
dated 26.02.98
Piston Crown Loss of Material on Combustion Side
RTA-39
dated 31.03.98
Overhaul and Reconditioning of Pistons
RTA-42.1 dated 14.03.2002 Templates for Exhaust Valve Seat and Spindle
RTA-43.2 dated 03.12.2002 Piston Rings
RTA-48
dated 20.09.99
Instruction for Replacement of NOx Relevant Components on IMO
Compliant Sulzer RTA Engines
RTA-55
dated 31.10.2001 Exhaust Valve Seat and Exhaust Valve Spindle
RTA-56
dated 26.02.2002 Indicator Valves
RTA-59
dated 10.02.2003 Procedures and Relevant Information for Sulzer RTA engines to comply with
the Annex VI NOx limit on Testbed and on Board
RTA-62
dated 21.05.2003 Prevention of Water CarryOver and Liner Polishing
RTA-63
dated 12.08.2003 Cylinder Oil Feed Rates
RTA-65
dated 25.09.2003 Daros ChromiumCeramic Piston Rings
RTA-66
dated 06.02.2004 Lubricating Oils
RTA-67.2 dated 03.03.2005 Lifting Device for Cylinder Liner
RTA-68
dated 06.12.2004 Piston Rod Gland Box Venting of the Oil Drain Collector
RTA-69
dated 22.03.2005 Air Spring Over Pressure - Relief Valve 274HD
RTA-70
dated 24.04.2005 Bolts for Piston Crown Spraying Plate and Piston Skirt
RTflex-1 dated 31.08.2005 Practical Tips Based on Service Experience
Should you not be in possession of the above mentioned documentation suitable for your plant, kindly contact
your local Wrtsil representative for your copy.

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Service Bulletin RTflex1

Return Parts Data Sheet for Investigation

Rcksendung-Datenblatt fr Untersuchung
The mentioned part is ask back for investigation to Wrtsil Switzerland Ltd.
Please send the completely filled in sheet to the contact person and also attach one copy of this
sheet to the returned component. Unidentifiable returns are rejected!
Name of Contact Person:
......................................................................
E-mail of Contact Person: ......................................................................@wartsila.com
Phone: +41 52 262 .. ..
Notification No.: ........................(WCH Internal)
Fax: +41 52 262 .. ..
Name of Installation:

Company Name:

Engine Type:

Engine No.:

Internal use only:

Total Engine Running Hours:

Running Hours of Component:

Name of Component Returned:

Serial No.:

Date of Incident / Removal:

Removed from Location (Cylinder #)
Order / Reference No.:
Description of Damage / Sequence of Damage:

Possible Reason of Damage:

Return from:

Return by:

(To be filled in by Wrtsil Switzerland only)

What to be investigated and by whom:

(To be filled in by Wrtsil Switzerland only)

Acc. #

Remarks:

Place of Shipping:

Date:

Signature:
Shipping Address:

Logistic Wrtsil Switzerland

Sulzer Allee, Geb. 571, Tor 3 (Warenannahme)
CH-8404 Winterhur
Switzerland

Service Bulletin Enclosure RTflex1.1

Data Sheet for WECS-Modules

Please fax this form to Wrtsil Switzerland Ltd, Fax No. +41 52 262 07 31 and attach copy with returned
component. If possible attach flexView printscreen to indicate malfunction.
Name of Contact Person:
E-mail of Contact Person:

......................................................................
......................................................................@wartsila.com

Name of Installation:

Company Name:

E / M / H Date (Software ID, see flexView Diagn. Page):

Date of Incident / Removal:

Module S/N:

Total Engine Running Hours:

Running Hours of Module:

(See flexView Diagn. Page)

Return from:

Return by:

MCM
-

CCM

CAN Bus Failure

FlexView Alarm:
- Bus Failure CAN #..........

FlexView Alarm:
- Bus Failure CAN #..........

Analog-In Error

- All analoge data out of range

FlexView Alarm:
- Control oil pressure, Meas. fail.
- Fuel rail pressure ......... Meas. fail.
- Servo oil pressure ......... Meas. fail.
- Charge air pressure ......... Meas. fail.

- CYL-EU Crank angle ......... Fail.

- Crank angle diff., Cyl. ......... Only on 1 cyl.!

Input Error

Digital-In / -out Error

FlexView Alarm:

- Digital input defective (RC-cmd, leak-alarm, ...)

- Digital output defective (Ctrl oil Pp, LI out, ...)

- Fuel qty. sensoe, Meas. fail.

- Exh. v/v sensor .......... Meas. fail.

Internal Error

- TDC signal failure

- Exh. Ch. ......... defective (no VDM-LED response)

- Start valve 24V out defective
- Servo oil pump setp. out (PWM) defective

Output channel Error

FlexView Alarm:

- Inj. Ch. .......... defective

- Servo oil pump # ........ , Actuator signal fail.

- Exh. Ch.. .......... defective

Other HW Error

- Cyl. #.......... Failure

- On-time feedback failure

Pls. descibe error details:

LED indications:
on / off / flash

2 f Inj. 1

on / off / flash

3 f Inj. 1

LED indications:
1 f CAN 1

on / off / flash

2 f CAN 2

on / off / flash

on / off / flash

3 f PWR CTRL

off

on / off / flash

4 f PWR DRVR

on / off

on / off

5 f FAIL

on / off

on / off / flash

4 f (Not applicable)
5 f Exh.
6 f Fail.
7 f Power

Other HW Error
FlexView Alarm:

- Power supply failure

1 f Inj. 1

Output Error
- Inj. Ch ........ defective (no VDM-LED response)

VDM

SSI Bus Failure

FlexView Alarm:

FlexView Alarm:
- COM EU #.......... Fail.
- Both or none COM EU are Master
- COM EU #.......... Identification error

CAN Bus Failure

ASM
-

MCM Selector failure

No RC-fuel command to WECS
No power supply for fuel cmd. backup ctrl.
Bus selector failure
SLD/SHD/Ctrl oil Pp. output missing

LED indications:
1 f Power

on / off

2 f ASM OK

on / off

3 f MCM 1 Master on / off

4 f MCM 2 Master on / off
FlexView Alarm:
- COM EU, ASM10, Failure

Service Bulletin Enclosure RTflex1.2