RT-flex82 Hyh-Pneu Rev.00

RT-flex82
RT-flex82 Training
Function of the different
Hydraulic- and Pneumatic
Components
Chapter 130_Rev.00
Wrtsil Land & Sea Academy
Page 1
Chapter 130_Rev.00
23-Jun-09
RT-flex82
Overview
Main Functions
Exhaust Valve Control
Starting Valve Control
Injection Control
Auxiliary Functions
Servo oil pressure control
Fuel pressure control
Valve stroke measurement
ICU stroke measurement
Crank angle detection

Page 2
Chapter 130_Rev.00
23-Jun-09
RT-flex82
Injection Control Unit (ICU)

Fuel Quantity
Sensor
To Injectors
The ICU controls the timing and volume

of the injection.
Each ICU has 3 rail valves to precontrol its own injection control valve.
The injection control valves control the
movement of the fuel quantity piston.
Servo Oil Return
Rail Valves
Page 3
Chapter 130_Rev.00
23-Jun-09
Servo Oil
from VCU
RT-flex82
ICU
Servo oil
supply 200 bar
WECS-9520
control
Supply Unit
Fuel Supply Pump
Page 4
Chapter 130_Rev.00
23-Jun-09
RT-flex82
ICU Cross-Section
Page 5
Chapter 130_Rev.00
23-Jun-09
RT-flex82
ICU Cross-Section
To Injectors
Quantity Piston
Quantity Sensor
Lip Seals
Aluminium Tube
From Fuel Rail
Page 6
Chapter 130_Rev.00
23-Jun-09
RT-flex82
ICU Cross-Section
Injection Control Valves
Distance Piece
Control Pistons
Rail Valves
Page 7
Chapter 130_Rev.00
23-Jun-09
RT-flex82
ICU
Page 8
Chapter 130_Rev.00
23-Jun-09
RT-flex82
ICU
Page 9
Chapter 130_Rev.00
23-Jun-09
RT-flex82
ICU
Page 10
Chapter 130_Rev.00
23-Jun-09
RT-flex82
ICU
Page 11
Chapter 130_Rev.00
23-Jun-09
RT-flex82
ICU
Page 12
Chapter 130_Rev.00
23-Jun-09
RT-flex82
ICU
Page 13
Chapter 130_Rev.00
23-Jun-09
RT-flex82
ICU
-> Back to
Return Position
<<
Page 14
Chapter 130_Rev.00
23-Jun-09
RT-flex82
Fuel Overpressure Regulating Valve

Fuel overpressure regulating valve:
In case of the fuel pressure in fuel common rail
pipe rises to ~1050 bar, the overpressure
regulating valve releases fuel to the fuel return
line.
The opening pressure is pre-adjusted by valve
manufacturer. Shims are used to give the right
position to the knurled screw, means if the screw
is fully screwed down to shims, 1050 bar are
set.
The min. opening pressure, means when knurled
screw is screwed fully out, is around 500 bar
(engine still operational).
During normal operation, main bearing oil
pressure keeps the valve closed. When the
opening fuel pressure is reached, main bearing
oil is released, pressure above piston drops and
fuel is released.
Page 15
Chapter 130_Rev.00
23-Jun-09
RT-flex82
Shutdown Valve
Engine shutdown function:
Solenoid valve leak

drain
Shutdown
Solenoid
valve
Oil filter
A shutdown is initiated by energizing the

solenoid valve (energized from safety
system, not WECS). In this way, main
bearing oil pressure above piston is
released, resulting in fuel pressure drop
down engine stops
MB-oil
supply
Piston
Lever for
manual depressurising
for maintenance work
Safety Valve
(1250bar)
Overpressure Control
Valve and Shutdown Valve
Fuel Rail Pipe

Page 16
Chapter 130_Rev.00
23-Jun-09
RT-flex82
(exhaust) Valve Control Unit (VCU)
Page 17
Chapter 130_Rev.00
23-Jun-09
RT-flex82
VCU
Page 18
Chapter 130_Rev.00
23-Jun-09
RT-flex82
To EXV
VCU
Rail Valve
Slide Rod
The VCU sits directly on the servo rail.

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 Piston (actuator pipe).
To ICU
Servo Oil
Piston
Filter insert
Internal Orifice
plug inside
Page 19
Chapter 130_Rev.00
23-Jun-09
RT-flex82
VCU (general working principle)
The valve control unit is pre-controlled by the rail valve.

At a certain crank angle, it gets an exhaust valve open
impulse signal from WECS. Servo oil flows via rail valve
to the lower side of the Slide Rod and moves 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 Slide
Rod moves down by mechanical spring, 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.
the exhaust valve is closing
Due to certain control bores, the VCU- piston has a
progressive movement. Means, it starts to move fast
and slows down, as it gets closer to the end stop.
Page 20
Chapter 130_Rev.00
23-Jun-09
RT-flex82
VCU
Rail valve
Slide rod
Piston
Exhaust valve
Servo rail
Position sensor
Spring air
Page 21
Chapter 130_Rev.00
23-Jun-09
RT-flex82
VCU
Rail valve
Slide rod
Piston
Exhaust valve
Servo rail
Position sensor
Spring air
Page 22
Chapter 130_Rev.00
23-Jun-09
RT-flex82
VCU
Rail valve
Slide rod
Piston
Exhaust valve
Servo rail
Position sensor
Spring air
Page 23
Chapter 130_Rev.00
23-Jun-09
RT-flex82
VCU
Rail valve
Slide rod
Piston
Exhaust valve
Servo rail
Position sensor
Spring air
Page 24
Chapter 130_Rev.00
23-Jun-09
RT-flex82
VCU
Rail valve
Slide rod
Piston
Exhaust valve
Servo rail
Position sensor
Spring air
Page 25
Chapter 130_Rev.00
23-Jun-09
RT-flex82
VCU
Rail valve
Slide rod
Piston
Exhaust valve
Servo rail
Position sensor
Spring air
Page 26
Chapter 130_Rev.00
23-Jun-09
RT-flex82
VCU
Rail valve
Slide rod
Piston
Exhaust valve
Servo rail
Position sensor
Spring air
Page 27
Chapter 130_Rev.00
23-Jun-09
RT-flex82
VCU
Rail valve
Slide rod
Piston
Exhaust valve
Servo rail
Position sensor
Spring air
Page 28
Chapter 130_Rev.00
23-Jun-09
RT-flex82
Automatic Filter
Servo oil and control oil is fine filtered before it enters the pumps and hydraulics. The automatic filter
has cartridges of nominal 25 m. There is an bypass filter of 34 m mesh size.
The reason for filtering is to increase the lifetime and safety margin of all hydraulic components.
Control box with indications
Page 29
Chapter 130_Rev.00
23-Jun-09
RT-flex82
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 (0.38 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 (Over current, differential pressure
high etc)
Inside the box there are switches/buttons to switch from Operation to Adjust. For detailed information
please consult filter makers manuals.
Page 30
Chapter 130_Rev.00
23-Jun-09
RT-flex82
Air system
Air is used for:

Actuation of automatic start valve
Starting of engine
Spring air supply
Flushing of automatic filter for servo
oil
Oil mist detector (option)
Waste gate valve for LLT (option)
Page 31
Chapter 130_Rev.00
23-Jun-09
RT-flex82
Air supply
From starting air bottles (30 bar)

To air springs
From control air
supply (7-9 bar)
To automatic main
starting valve
through turning gear
@ (OMD)
@ (Waste Gate V/V)
Page 32
Chapter 130_Rev.00
23-Jun-09
RT-flex82
Control air supply unit
Page 33
Chapter 130_Rev.00
23-Jun-09
RT-flex82
Starting air
Page 34
Chapter 130_Rev.00
23-Jun-09
RT-flex82
Main Starting Valve
Page 35
Chapter 130_Rev.00
23-Jun-09
RT-flex82
Starting Pilot Valve
Page 36
Chapter 130_Rev.00
23-Jun-09

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RT-flex82

Starting Valve Control

Fuel pressure control

Valve stroke measurement

ICU stroke measurement

Crank angle detection

Injection Control Unit (ICU)

The ICU controls the timing and volume

Servo Oil Return

Wrtsil Land & Sea Academy

Wrtsil Land & Sea Academy

Wrtsil Land & Sea Academy

From Fuel Rail

Wrtsil Land & Sea Academy

Wrtsil Land & Sea Academy

Wrtsil Land & Sea Academy

Wrtsil Land & Sea Academy

Wrtsil Land & Sea Academy

Wrtsil Land & Sea Academy

Wrtsil Land & Sea Academy

Fuel Overpressure Regulating Valve

Wrtsil Land & Sea Academy

Engine shutdown function:

Solenoid valve leak

A shutdown is initiated by energizing the

Fuel Rail Pipe

Wrtsil Land & Sea Academy

(exhaust) Valve Control Unit (VCU)

Wrtsil Land & Sea Academy

The VCU sits directly on the servo rail.

Wrtsil Land & Sea Academy

VCU (general working principle)

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

Wrtsil Land & Sea Academy

Wrtsil Land & Sea Academy

Wrtsil Land & Sea Academy

Wrtsil Land & Sea Academy

Wrtsil Land & Sea Academy

Wrtsil Land & Sea Academy

Wrtsil Land & Sea Academy

Wrtsil Land & Sea Academy

Control box with indications

Wrtsil Land & Sea Academy

The back flushing is automatically initiated by the control box either

Wrtsil Land & Sea Academy

Air is used for:

Wrtsil Land & Sea Academy

From starting air bottles (30 bar)

Wrtsil Land & Sea Academy

Wrtsil Land & Sea Academy

Control air supply unit

Wrtsil Land & Sea Academy

Wrtsil Land & Sea Academy

Main Starting Valve

Wrtsil Land & Sea Academy

Starting Pilot Valve

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