International Symposium on Computers & Informatics (ISCI 2015)

The analysis and management of Wärtsilä

engine control system-9520
Yuan Renmin

Maritime College, Shandong Jiaotong University, Weihai 264200,

Shandong, China

yrm0019@163.com

Abstract.
In recent years, Wärtsilä RT-flex series electronic control diesel engine are
increasingly applied to the ship.In order to make more safely and effectively to
use, maintenance and management of the diesel engine, this paper mainly take
6RT-flex48T-D diesel engine as an example to introduce the RT-flex series
electronic control diesel engine control system .

Keywords：RT - flex;Electronic control technology;Marine diesel engine;Control

system;Use the management

Introduction
With the development of electronic control technology, control and
monitoring of electronic control technology is more and more widely used in
marine power plant.The RT-flex concept is based on the Wärtsilä common
rail.Using electronic common rail control technology,the whole design of
intelligent, modular. In the aspect of energy saving, environmental
protection, reliability, security and flexibility than the previous models has been
greatly improved, in line with the current energy efficiency control and emission
standard.

The composition of the control system

RT-flex48T-D diesel engine is used in the WECS-9520 control system.The
system adopts microcomputer control technology and fieldbus technology is
mature, the realization of electronic control and monitoring of diesel engine. The
redundant set are used in the module settings and distribution to ensure the
reliability of bus. The composition and the connection of WECS-9520 control
system shown in fig.1 and fig.2 .

© 2015. The authors - Published by Atlantis Press 943

 The control system of Flex function unit
As shown in Figure 1 the WECS-9520 control system of Flex junction box
mainly comprises:a power box(E85), electrical rail box (E95.01~06), power
distribution and external communication junction box(E90), local operation
junction box(E25), cylinder pulse lubricating junction box(E41.01~06), the
crank angle of the junction box(E96.1 and E96.2) and flexView software
computer etc. In figure E95.01~05 only painted on the connection machine
control function, 09~88 terminals with cylinder control function in E95.06.

Control and safety alarm unit

As shown in Figure 2 control and safety alarm connection box mainly
comprises: a servo oil self-cleaning filter junction box(E92), piston cooling oil
temperature monitoring terminal box(E111.1~3), piston cooling oil flow
monitoring terminal box(E28, E28.01~06), engine speed detection and junction
box(E20), super charger monitoring terminal box(E31), signal acquisition
box(E110, E120.1~2, E12,E114.1), diesel engine safety junction box(E10).

The function of the control system

The main functions of the control system are: common rail pressure control,
cylinder pulse lubricating control, fuel injection control, exhaust valve control,
start valve control, crank angle detection etc.

Common rail pressure control

6RT-flex48T-D type diesel engine fuel supply unit has 2 fuel pump and the 2
servo oil pump, hanging in the output end of the machine, directly through the
crankshaft gear drives.

944
From MSB From ESB
220V 220V
1 3 WECS Cylinder oiling
source
2
43
4 E85 45 47
fault
21
source fault
23 49 29 31 51 25 27 5341
44 46 48 22 24 50 30 32 52 26 28 5442
ECR flexView
WECS9520
manual ECR ME Cylinder oiling computer
control Maneuvring AMS Power or � ECR�
RCS panel source CAN-USB conversion
unit torque
CAN M#0
65 1 79 55 S+
66 2 80 56 S-
E90 40 44
41 45
51 03 55 57 53 05 81 63 07 59 61 09 69 67 31 33 85 11 13 49 57
52 04 56 58 54 06 82 64 08 60 62 10 70 68 32 34 86 12 14 50 58
sourcesource
1# 2# Cylinder oiling
C M M C C M M C Fuel pump 21 23 11/12Solenoid valve
A O O A A O O A Actuator 22 24
source
N D D N N D D N
C
E41.06-011314 Cylinder
pressure
oil
B B B B 25/26 27
M U U M M U U M A 28
# S S #2 #3 S S # A1 B1 N
C1 BDC A2 B2 C2 TDC C
1 # # # # 3/4 4 13 16 23
24
26
27
13 16
L 14 17
23
24
26 A
27 C
1 2 3 4 14 17 C
15 18 25 28 # 15 18 25 28 N
A A
E25 37
E96.1 1 E96.2 N N
37 L
1/2 38 11 31 33 38
11 31 33
#
S S
12 32 34 CAN 12 32 34 # #
2 2
source source source source sourcesource source sourceM#5 source source 1
55 S+ 63 63 55 S+ 37 55 S+ 63 63 S+ 37 55 83 95 S+ 55 83 55 S+
56 S- 64 64 56 S- 40 56 S- 64 64 S- 40 56 84 96 S- 56 84 56 S-
1# 2#
Fuel pump S S S S 09-12:Exhaust common rail valve open
92/93 actuator 92/93
position set S S S S 13-16:Exhaust common rail valveclose
17-20:1#common rail injection valve
1# 2# point I I I I inject
main starting 1# 2# # # # # 21-24:1#common rail injection valve
39/40 electromagnetic39/40 79/80 Fuel common 79/80 2 2 return
E95.01 valve
E95.02 E95.03 rail pressure
1# 2#
E95.04 1 1
D E95.05 C D inject
E95.06
25-28:2#common rail injection valve

35/36 Actuator servo 35/36 C A L A 29-32:2#common rail injection valve

1# 2# oil pump 89-91
L T From O T return
94/95 oil pressure 94/95 89/90 turning gear ia 89/90 E20 ME C A 33-34:the start pilot valve of Cylinder
servo signal O A TDC 68-72:The exhaust valve position signal
detection disengaged K
C 86-88:Fuel injection quantity signal
94/95 1# 2# 94/95
Scavenging K
51 53 59 61 49 57 51 53 59 61 49 57 51 53 59 61 49 57 gas collector 51 53 59 61 49 57 51 53 59 61 49 57 51 53 59 61 49 57
52 54 60 62 50 58 52 54 60 62 50 58 52 54 60 62 50 58 pressure 52 54 60 62 50 58 52 54 60 62 50 58 52 54 60 62 50 58
SSI #1 CLOCK
SSI #1 DATA
SSI #2 CLOCK
SSI #2 DATA
CAN S#1
CAN S#2

Fig.1 6RT-flex48T-D diesel engine WECS9520 Junction box wiring diagram

945
 n
a sl
g
ni u
r p
ot or
i p
n E20
E92 E110 o speed measurement sensor�
speed measurement sensor�
ST5101C�
ST5102C�
e
The servo oil self-cleaning The servo oil self-cleaning filter
failure m speed measurement sensor�
speed measurement sensor�
ST5103C�
ST5104C�
h
T
filter failure
The servo oil unit leakage speed measurement sensor� ST5111S�
1#� 2#The servo oil pump flow speed measurement sensor� ST5112S� E25
Source from E95.04
The outlet temperature of the thrust
connect CAN M#04
bearing lubricating oil ME TDC signal
Auxiliary blower starting
The axial damper back-end oil
order
pressure
Auxiliary blower runing
The axial damper fore-end oil
indicator
pressure E120.2 engine room order
Supply unit fuel inlet temperature
Main engine revolution
Leakage of fuel oil supply unit
Jacket cooling water inlet indicator
Common rail unit total leakage
temperature Emergency stop button
The fuel injection control unit/fuel
pipe leaks
1#-6# cylinder cooling water
outlet temperature
E28.01 E28
1#� 2#� 3#� 4#� 5#� 6# cylinder 1#Piston cooling oil flow switch
the temperature of charge air 1#Piston cooling oil pressure switch 1/2

m
1#� 2#Cylinder piston Air cooler cooling water inlet
E111.1 cooling oil outlet temperature
E28.02
o
1#� 2#Cylinder piston cooling oil
temperature Air cooler cooling water outlet
outlet temperature

or
temperature 2#Piston cooling oil flow switch
3/4
3#� 4#Cylinder piston 2#Piston cooling oil pressure switch
Scavenging temperature after
E111.2 cooling oil outlet 3#� 4#Cylinder piston cooling oil
temperature outlet temperature
air cooler
1#-6# Cylinder exhaust
E28.03
5#� 6#Cylinder piston temperature 3#Piston cooling oil flow switch
5/6
E111.3 cooling oil outlet
temperature
5#� 6#Cylinder piston cooling oil
outlet temperature
exhaust temperature before
3#Piston cooling oil pressure switch

turbo-charger
exhaust temperature after
E28.04
E12 turbo-charger 4#Piston cooling oil flow switch
4#Piston cooling oil pressure switch 7/8
Scavenge box pressure� E95.03�
E95.04 E120.1 The turbo-charger outlet temperature of
the lubricating oil E28.05
Cylinder liner cooling water inlet The turbo-charger lubricating oil inlet
9/1
5#Piston cooling oil flow switch
Cylinder liner cooling water inlet pressure pressure 5#Piston cooling oil pressure switch 0
pressure The air cooler cooling water inlet
The air cooler cooling water inlet pressure E28.06
pressure Piston cooling oil inlet pressure 6#Piston cooling oil flow switch 11/1
Piston cooling oil inlet pressure Supply unit fuel inlet pressure 6#Piston cooling oil pressure switch 2
Supply unit fuel inlet pressure Air spring pressure
Air spring pressure Control air pressure E10
Control air pressure Main bearing lubricating oil inlet Fuel stop valve
Cooling water inlet pressure switch
Lubricating oil inlet pressure switch
temperature
Servo hydraulic cylinder lubrication E31 Turning machine off switch position
Thrust bearing lubricating oil outlet
The turbo-charger outlet temperature of the
Air spring pressure switch Servo cylinder lubrication oil spill oil temperature switch
lubricating oil
Starting air pressure pressure The turbo-charger lubricating oil inlet
The main starting valve closed position
The cylinder lubricating oil filter pressure switch
pressure difference
E114.1 Air spring lubricating oil leakage
The turbo-charger speed
The turbo-charger oil inlet pressure switch
The supercharger oil import pressure
switch
liquid level switch turbo-charger speed
Air cooler separator condensate Air cooler condensate water
liquid level switch. leakage switch Cylinder liner cooling water inlet
pressure switch
Main bearing lubricating oil inlet
Four liquid level switch is normally pressure switch
closed contacts in series. Air spring pressure switch
The main starting valve before starting
air pressure

Fig. 2 6RT-flex48T-D diesel engine control safety alarm junction box wiring diagram

The common rail fuel pressure is changed with the diesel engine load has
been shown in fig.3.WECS-9520 according to engine speed and fuel command,
calculate the diesel engine load and calculated according to the load size to
generate a pressure setpoint signal, by FCM-20 #3 and #4 module compared to
two sets of common rail pressure sensor detects the pressure value and the
external control system of fuel instruction to calculate fuel pump actuator

946
adjustment instruction, by Woodward oil amount adjustment actuators pull the
fuel pump rack.

Fig. 3 the common rail fuel pressure set value

The control of servo oil pressure is also based on engine load changes, the
set value signals produced by FCM-20 #3 and #4 respectively control pressure
control mechanism of two servo pumps.Servo oil common rail pressure is
feedback to FCM-20 #1 and #2 respectively detected by two pressure
sensors.The common rail pressure was controlled between 80~190bar.

Electronic cylinder pulse lubricating

Cylinder lubrication system is by FCM-20 #5 and #6 according to the crank
angle signal and the diesel engine load issued injection timing and fuel injection
quantity control commands to the ALM-20 #1~#6 control injector solenoid
valve to perform the oiling action.And by the oil pressure sensor feedback oiling
success.

Fuel injection control

Each cylinder FCM-20 Module according to the fuel command, crank angle
signals and from the governing system received their timing calculation.Before
the TDC, considering the VIT and FQS signals, calculate the precise injection
angle, and the issue of fuel injection start and end of the instruction to the two
common rail fuel valve to control fuel injection action ICU.

Exhaust valve control

The exhaust valve is opened by the servo hydraulic, and closed by an air
spring pressure. Exhaust valve stem movement monitored by the position sensor,

947
and give feedback to the control module.

The start valve control

The two main starting electromagnetic valve is respectively controled by
FCM-20#1 and #2 according to the remote control system command sends
control signal.

The using and management

The system control module
In the process of using the machine vibration is caused extremely easily
loose system terminal, work pay attention to frequently check terminal. If
the system is abnormal but after inspection found no cause of the malfunction,
can be in this module off a few seconds, and then resupply. If normal, you can
continue to use.If there are problems, replace the standby module.

Fuel pump actuator

In the daily maintenance, through the“Fuel Pump Actuators Position Test”
command in the flexView user interface to test fuel pump actuator action, can
test three positions:0%, 50%, 100%. In the diesel engine operation process, can
be manually forcing one actuator mechanism, observation of another actuator
whether automatic adjustment to the opposite direction, let go after two and will
automatically return to the original position. If one actuator fault available
special tools (distance piece) the fuel pump rack fixed position in 0, 50% or
100%, the fuel supply at this time is not adjustable, common rail pressure is
adjusted by another, diesel engine load were restricted to 0~40%, 20~80%,
40~100%.

Common rail valve

Common rail valve is a bistable uses high speed response of the 2 position 3
way valve. According to the rules given in the WECS-9520 directives, common
railvalve coil to produce a high current pulse in a short period of time(50~60A),
the spool moves about 0.3mm displacement. Large current pulse and short spool
displacement ensures a very short reaction time, so as to achieve precise control
of fuel injection and exhaust valve.

948
 Parameter adjustment
The control flexibility of electronically controlled diesel engine lies
in through flexView can be adjusted conveniently on the important control
parameters, to improve the work performance.
“Base Feed Rate@CMCR”: the six cylinder rated load quantity of oil
injection respectively adjusted, can use the "Set all" to modify the six
cylinder unity. The adjusting range of feed rate is 0.6g/kwh~1.6g/kwh, the value
is out of range will be displayed in red. On the basis of actual feed rate with the
diesel engine load and variable.
“Exvclosing Offset”:By changing a cylinder exhaust valve closing angle, to
balance the cylinder compression pressure. The adjusting range of the parameters
for -3.0~+3.0<0, six cylinder compensation value average value should be
between -0.2~+0.2<0.
“InjBegin Offset”:By changing a cylinder fuel injection angle to regulate
the detonation pressure of each cylinder, load balance. Fuel injection angle
compensation is divided into two levels: -0.5~+0.5<0, -1.5~+1.5<0. The six
cylinder compensation value average value should be between -0.2~+0.2<0.

Summary
Now the new ship in the host application more and more electronic control
diesel engine, electronic control diesel engine technology is becoming more and
more perfect. The engineers to learn and understand the electronic control
technology for diesel engine. Believe that with the continuous improvement
of this series diesel engine knowledge and the accumulation of management
experience, the electronically controlled diesel engine can fully play the
advantages.

Reference
[1] Wärtsilä Switzerland Ltd.Wärtsilä RT-flex48T-D Operating Manual [M].
2012 .

[2] Wärtsilä Switzerland Ltd.Wärtsilä RT-flex48T-D Maintenance Manual [M].

949
 2012.

[3] Wärtsilä Switzerland Ltd. Operator flexView Manual Revision 3.0 [M].2012.

[4] Wärtsilä Switzerland Ltd, RT-flex Training:Function of the CLU-4 Pulse

Feed Cylinder Lubrication System[M].2012.11

[5] Wärtsilä Land & Sea Academy .RT-flex Training:RT-flex Bus Systems

950