Wärtsilä Switzerland Ltd= oqJÑäÉñ=póëíÉãë=

Author Edwin Fullagar Dept. 10188 Tel. 22453 Date 17/08/2006 Page 1 / 11
Subject

Operation Manual for Dynex-type servo-oil pumps.

1 Reason for document

In normal service, Dynex servo-oil pumps are unlikely to require any special attention. Many
of the components used are very robust and have proven themselves over many thousands
of service hours on Wärtsilä RT-flex 2-stroke engines. However, should problems be
encountered, it is important that the operator understands of the principle of operation of a
Dynex pump in order to make good in-service judgement.

The main body of the pumps, including the swashplate, bearings, pistons, piston
shoes and pump valving should not be dismantled. If it is suspected that a problem
exists in these parts, the pump should be removed from service and servicing
undertaken by specifically trained Wärtsilä service personnel. For this reason, this
document covers only the Dynex control system.

2 different Dynex pump types exist, the smaller pump used on the RT-flex50, RT-flex58, RT-
flex60 and RT-flex68 engines is of the type PV6070 and the larger Dynex pump used on the
RT-flex84 and RT-flex96 engines is of the type PV7190. Both pumps use an identical system
of operation to regulate the servo-oil system pressure and flow, however, some significant
differences exist between the pump controls concerned. Additionally, there are several small
differences in the execution of the smaller PV6070 pumps.

2 Description of Process
The Dynex pumps operate using a fixed-stroke, axial piston system, whereby the stroke of all
the pistons is always the same, irrespective of the flow output of the pump. The flow into
each cylinder is controlled by a pair of check-valves, the inlet check-valve and the bypass
valve. The flow out of each cylinder is controlled by the outlet check valve and the bypass
valve. Figure 1 presents the system of operation.
Proportional valve

Inlet check valve Outlet check valve Control Circuit

Orifice 1
Orifice 2

Bypass check valve

Overpressure
safety valve

Control circuit
safety valve
Orifice 3

Regulating space
= =
Page: 2 / 11
Date: 17/08/2006=

Figure 1 – Dynex Schematic (PV6070)

The 3 check-valves in each cylinder work as follows:

Inlet check-valve:
• Located inside each piston, these allow oil to flow into the cylinder as the piston is
moved out of the cylinder. Once the piston is at bottom dead centre, the check-valve
will close, preventing flow through this valve during the compression stroke of the
piston.

Outlet check-valve:
• Located at the top of each cylinder, these allow for oil at high pressure to pass to the
high-pressure side of the pump during the compression stroke of the piston. If the
cylinder pressure is lower than the outlet pressure of the pump, no flow through this
valve will take place.

Bypass check-valve:
• Located next to the outlet check valve of each cylinder, this valve controls whether the
oil in the cylinder is returned to the low-pressure side of the pump or is forced out of
the high-pressure side of the pump during the compression stroke of the cylinder.
• This valve can be held off its seat by the control pressure of the pump, which is
regulated by the pump compensator, however, once it shuts it will not re-open until the
end of the compression cycle, as the high cylinder pressure will force the valve to
remain shut.
• As this valve will not open again once it has closed during the compression stroke of
the piston, the flow which is forced through the outlet check-valve is controlled by the
position of the piston when this valve touches its seat. If this valve touches its seat
very early in the compression stroke of the piston, the flowrate of the pump will be
near maximum, if this valve touches its seat when the piston is at the end of its
compression stroke, the flowrate from the pump will be near minimum.
• Clearly the control pressure of the pump regulates at what time during the
compression stroke the bypass check-valve opens and closes, which in turn regulates
the output flow from the pump. If the control pressure is high (more than around 5bar
relative to the inlet pressure of the pump), the pump will deliver no flow at all. If the
control pressure is low, the pump will deliver with maximum flow. The control pressure
of the pump is controlled by the pump compensator, which is the primary focus of
discussion in this document.

Operation of Pump Compensator

As can be seen in Figure: 1, the oil enters the pump compensator (shown at the right of
Figure: 1) through a small orifice (orifice 1) and can pass one of 2 ways:
1. Through a proportional valve (the normal way).
2. Through an overpressure safety valve.

If the pump outlet pressure is high enough, the oil will force its way through the proportional
valve (the force from the proportional valve depends upon the electrical pressure setpoint of
the pump) and into the control circuit of the pump. The pressure in the control circuit is

Revision 1, E. Fullagar 17/08/2006.

= =
Page: 3 / 11
Date: 17/08/2006=

maintained as a balance between the flow through the proportional valve and another orifice
(orifice 2) to the pump inlet pressure (drain). One more orifice (orifice 3) between the pump
compensator and the pushrods for the bypass check-valves does not regulate the pressure
so much as the response speed of the pump. In this way, the control pressure of the pump is
a balance of the electrical current to the proportional valve and the outlet pressure of the
pump.

In the event that very high pump pressure occurs, (for example if the proportional solenoid
current is too high), the overpressure safety valve will open and oil will pass directly to the
control circuit and reduce the pump flow. In this case, the proportional valve is short-
circuited. The larger 7190 pumps have a device to open this valve and dump the pump
pressure in the event of a problem such as a cracked high pressure pipe. This device,
called a “dump valve”, can be used to reduce the outlet pressure of the pump to the
inlet pressure plus about 10bar.

3 Differences between Dynex 6070 and 7190 pumps

The method of operation of both pumps is identical, however the larger pump has some small
improvements to increase the control reliability, reduce sensitivity and improve maintenance.
Specifically, this means:
1. A small protection filter to protect the fine compensator orifices from the potential of
blockage is incorporated into the compensator block.
2. Orifices 1 and 2 are built into the compensator block, not the rear plate of the pump
as on the smaller pumps.
3. The control circuit safety valve is now non-adjustable and is located at the back of the
compensator assembly.
4. A “dump valve” feature has been added to the overpressure safety valve to reduce
the pump delivery pressure to approximately 15bar in the event of an emergency or
test.

These features will be discussed and documented later in this document.

The control of the pump is very simple, effective and reliable.

4 Options of the Dynex pump control

If in the event of an emergency, test or engine commissioning it is necessary to manipulate
the pump control, the following options are available:
1. Reduce the delivery pressure of a pump to approximately 15bar (above which there
will be no flow). On the larger PV7190 pumps this is called the “dump valve”
2. Force the pump to deliver at the maximum delivery pressure, as set by the
overpressure safety valve (normally 240bar, above which there will be no flow).
3. Adjust the minimum delivery pressure of the pump (normally 80bar, above which there
will be no flow).

Revision 1, E. Fullagar 17/08/2006.

= =
Page: 4 / 11
Date: 17/08/2006=

These are the only possibilities available for Dynex-type pumps, as installed on Wärtsilä’s
RT-flex engines.

1. Reducing the delivery pressure

a) PV7190 (big pump)
The delivery pressure of the larger PV7190 pumps can be reduced to approximately
15bar by use of the “dump valve”. The dump valve can be activated using a 22mm
spanner to unscrew the top section of the valve shown in Figure: 2. The top section of
this valve can be unscrewed to the end, it will not come off. In the event that the top
section of the valve is tight, it may be necessary to hold the main body of the valve with
another 22mm spanner, to prevent that it also unscrews (note that the main body is
nevertheless secured by a retaining screw).

Overpressure safety
valve setpoint.
DO NOT ADJUST

Dump valve
(yellow) 22mm

Main body of
valve

Figure: 2 – Dump valve of PV7190 pump

To return the pump to its normal operating condition, simply tighten the dump valve
again.

b) PV6070 (smaller pump)

The delivery pressure of the smaller pump can be reduced in the same way as it is for
the larger PV7190 pumps, however there is no convenient “dump valve”. In the case
of these pumps, the maximum delivery pressure can be reduced by unscrewing the
housing of the Overpressure safety valve. This operation will require a 7/8” open-
ended spanner. It is of the utmost importance that the housing is not unscrewed
by more than a maximum of approximately 2 full turns, otherwise the housing
may come out completely! As with the larger pump, it is important that the locknut

Revision 1, E. Fullagar 17/08/2006.

= =
Page: 5 / 11
Date: 17/08/2006=

and setting of the maximum delivery pressure is not disturbed. Figure: 3 shows how to
unscrew the overpressure valve housing.

Control circuit
safety valve

Figure: 3 – Unscrewing the overpressure safety valve housing (compensator block is shown removed
from pump with solenoid removed). Unscrewing this housing by not more than 2 full turns will reduce
the maximum delivery pressure of the pump to approximately 15bar. Access to this valve housing is
quite limited, so it is recommended to use an open-ended spanner (not a ring spanner, as shown). The
valve housing size is 7/8” A.F., some 22mm spanners may also fit. Do not confuse this valve housing
with the control circuit safety valve (shown with two locknuts)!

2. The delivery pressure of either the big PV7190 pump or the smaller PV6070 pump can
be set to maximum (approximately 240bar) by turning in the adjusting screw at the top
of the solenoid as far as possible. Care must be taken that the adjusting screw is not
made too tight, which may damage the valve seat. This is shown in figure:4.

Revision 1, E. Fullagar 17/08/2006.

= =
Page: 6 / 11
Date: 17/08/2006=

Control circuit
safety valve –
Caution when
removing,
7.14mm ball
can be easily
lost!

Figure: 4 – Forcing the pump to deliver at full flow up to maximum pressure (approx 240bar) can be
achieved by screwing in the adjusting screw as shown as far as possible. Care must be taken not to
overtighten the screw, damage to the valve seat can result. The process is the same for both PV6070
and PV7190 pumps. On very early versions of the smaller PV6070 pumps, this screw is the minimum
pressure setpoint of the pump.

When loosening the adjusting screw again, the screw position is not critical, it must
only be screwed well away from the valve seat (approximately 2 full turns is enough).
The locknut must always be tightened to hold the final solenoid position.

3. The minimum pressure setpoint of the pump is adjusted as shown in Figure: 5. This
requires a 3/16” Allen key (no metric key will fit) and a 9/16” spanner (an adjustable
spanner and some 14mm spanners will also work).

Revision 1, E. Fullagar 17/08/2006.

= =
Page: 7 / 11
Date: 17/08/2006=

Figure: 5 – Adjusting the minimum pressure setpoint of the pumps (shown in figure is the larger PV7190
pump compensator assembly). On very early versions of the smaller PV6070 pumps, this adjustment point
did not exist and the minimum pressure was adjusted as shown in figure 4.

In order to effectively adjust the minimum pressure setpoint, a clear understanding is

required of how several pumps operating in parallel with at least one redundant pump
will respond. In general, the pumps should be adjusted at this point so that when all
cables from all pumps are removed, the pressure is maintained at approximately 80bar
and the same flow can be measured at the flow meter of each pump. This becomes
more difficult as the total number of pumps installed on an engine increases.

5 Troubleshooting a Dynex pump

Generally speaking, the most likely time for problems to occur with Dynex pumps is during
shoptest, seatrial or after maintenance of an engine. This is because contamination
introduced when the engine is new or after maintenance can upset the sensitive pressure
balances in the control circuit of the pump. This problem has been alleviated somewhat by
the introduction of a small filter, integrated into the compensator of the larger PV7190
models. This filter is shown in Figure: 6.

Revision 1, E. Fullagar 17/08/2006.

= =
Page: 8 / 11
Date: 17/08/2006=

Filter cavity
(top of PV7190
compensator
assembly).
Plug (10mm
hex), spring
and filter.

Figure: 6 – Removing the compensator filter (approx. 50µm) installed in the DynexPV7190 pumps. The dirt
trapped in this filter gives a lot of information about the effective level of filtration normally applied to the engine
in service. In normal operation, this filter should be completely clean. The smaller PV6070 pumps do not have
this filter and are thus much more susceptible to the ingress of dirt.

It is also possible that changes to the WECS control system can change the pressure
response and/or control of the Dynex pumps. For this reason, any flow balancing and/or
testing of the Dynex pumps should be done with the electrical cables removed from
the pumps, if possible.

This following table deals with different Dynex control problems and how to fix them. Due to
the small and critical nature of the parts concerned, it is highly recommended that the
pump compensator is removed from the pump before disassembly.

Symptom Possible Cause Remedy

Pump does not deliver 1. Orifice #2 of the pump compensator has Stop engine, remove orifice #2 and clear it. See Figures 7a
at any setting of the become blocked. and 7b.
minimum pressure 2. Dump valve or overpressure safety valve Check that valve is screwed in correctly and dump valve is
setpoint screw. loosened or not seating correctly. closed. If OK, stop engine and remove valve carefully to
Pump surface will inspect and clean valve parts.
A become warm after
some time, but should 3. System is already at overpressure due to Problem is with another pump.
stabilise at 65-75°C. Do problem of another pump delivering at full
not allow the pump flow.
temperature to rise 4. Serious internal failure of the pump. Stop engine and remove pump, get qualified service
above 90°C. personnel to check pump.
B Pump delivers at full 1. Orifice #1 of the pump compensator has Stop engine, remove orifice #1 and clear it. See figures 8a
flow at any setting of become blocked. and 8b.
the minimum pressure 2. Control circuit safety valve is unseated or UNLIKELY. Re-adjusting of this valve will be very difficult
setpoint screw. has be incorrectly adjusted. on smaller PV6070 pumps (see “Control circuit safety
valve” in Figure: 3), best solution is just to turn the adjusting
screw in until the pump works, then turn screw in
approximately 1 full turn further and check that the pump

Revision 1, E. Fullagar 17/08/2006.

= =
Page:
Date:
3. The screw at the top of the compensator
solenoid has been screwed all the way in.
4. The proportional valve poppet is blocked
or stuck in its seat.
5. System is already at underpressure due
to another pump not delivering at all.
Pump flows balanced 1. “Correction” applied to pump setpoints in
when solenoids not WECS.
connected,
unbalanced when
C
connected. 2. At different pressures, the load balancing
of the pumps will change slightly. This is
normal. Some load balancing should
always take place, however.
Pump flow is erratic or 1. Pump inlet is restricted or supply pressure
unpredictable. is too low.
2. Presence of air in pump compensator.
D 3. Presence of dirt in pump compensator
control circuit or inside pump regulating
space.
4. Pump is compensating for a different
pump or problem in the system.
Figure: 7a – Removing Orifice 2 from the PV7190 (big Figure: 7b – Removing Orifice 2 from the PV6070
Dynex pump) compensator. View is from the (small Dynex pump) compensator. Yellow plastic plug
underside of the pump compensator. Hex key size is (as shown) or plugging screw must be removed for
Revision 1, E. Fullagar 17/08/2006.
9 / 11
17/08/2006=
operates correctly through the full engine load range. See
Figure: 5 for bigger PV7190 pump valve, which cannot be
adjusted.
See Figure: 4 and slacken this screw at least 2 full turns.
The final position of this screw is not important (unless the
pump is a very early PV6070 type).
Stop engine and remove solenoid to inspect valve poppet
and/or seat.
Problem exists with another pump.
Set all “corrections” to 0.0bar, then remove all pump
solenoid cables and re-adjust all pumps. These can be
found on the “ADJUST” page of Flexview with the name
“ServOilPump PrSetPt”.
No need for action.
Check supply pressure, sizing of pipes and pipework for
blockages or restrictions.
UNLIKELY - Drain the air from the control system using the
small drain screw in the pump solenoid and the control port
in the pump regulating space.
Stop engine, remove compensator and control plate at rear
of pump and clean circuits of both pump compensator and
regulating space. Pump compensator can be cleaned by
removing one or both of orifices 2 or 3 and blowing air
between them. See figures 9a and 9b to remove orifice #3.
Could be an exhaust valve not opening or one of points 1,2
or 3 with another pump on the engine.
= =
Page: 10 / 11
Date: 17/08/2006=

5/64”. access to orifice screw, which is removed using a flat-

bladed screwdriver.
See symptom A1 in the troubleshooting table for reference to the pictures above.

Figure: 8a – Removing Orifice #1 from the PV7190 Figure: 8b – Removing Orifice #1 from the transfer
(big Dynex pump) compensator. Hex key size is tube located between the control plate and the pump
5/64”. on the PV6070 (small Dynex pump). Hex key size is
5/64”. Please note that in normal practice it is possible
to clean the orifice without removing it from the
transfer tube.
See symptom B1 in the troubleshooting table for reference to the pictures above.

Revision 1, E. Fullagar 17/08/2006.

= =
Page: 11 / 11
Date: 17/08/2006=

Figure: 9a – Removing Orifice #3 from the PV7190 Figure: 9b – Removing Orifice #3 from the control
(big Dynex pump) compensator. Hex key size is plate of the smaller PV6070 pump. On the other side
5/64”. of this screw is the regulating space of the pump.
See symptom D1 in the troubleshooting table for reference to the pictures above.

Revision 1, E. Fullagar 17/08/2006.