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RT-flex82

RT-flex82 Training
flexView-9520
for Operators

Chapter 150_Rev.00
Wrtsil Land & Sea Academy

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Aim of the Training

Aim of the Training


The trainee should understand the function of flexView and meaning of its
displays.
Trends can be created.

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Basic Information

Basic information about flexView:


flexView is the visualisation tool of WECS-9520, it runs on a standard
Windows PCs.
It can be started like a normal Windows program by selecting the
icon on the desktop of the PC.
The PC in the ECR can be connected to WECS-9520 by using a CAN
USB converter.
It is recommended to leave the PC on and connected the whole time.
Service engineers can hook up their Notebooks via the Service Port in
the ECR panel.

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flexView connection

flexView connection at the manual control panel in ECR


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CAN USB converter

CAN USB converter

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Levels of Access

flexView has different access levels, controlled by USB dongles of different


colours.
Blue:

Crew, Operator

Green: Commissioning
Red:

Developer

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flexView Window

The flexView window is divided in two separate main-cards where different


sub-cards can be select from the menu row on top of each card.
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flexView Window

The two standard cards Indic and Journal are shown by default when the
program is started. These two cards show all necessary data for the average
daily use at sea or during manoeuvring.
Indic(-ation) displays the actual engine speed, fuel command, common rail
pressures and some general injection and exhaust valve timing data.
Journal displays engine related failures and indications with time stamps for
occurrence, acknowledging time and restoring time. For a quick reference the
different indication groups have a colour code for easy separation of the groups.

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flexView Window

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Shut down on Safety System or
WECS-9520 Critical Failure
Rail Pressure Failures
Cylinder Failures
Common Failures
Passive Failures
Events

Failure Log Journal


The failure log shows the same that are transmitted via CAN- or
ModBus to the Alarm Monitoring System.
Additionally events are shown that help to relate failures to actual
manoeuvring conditions.

Overview of active
failure groups

Background colour of active failures is failure type colour.


Restored failure logs have white background colour.
A checkbox allows hiding restored failure logs.
Background colour of new failures is failure type colour.
Acknowledged failure logs have white background colour.
A checkbox allows hiding restored failure logs.

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Select a failure with mouse-click and press


Shift+Enter to acknowledge.
All failures are transmitted to the Alarm
Monitoring System.

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Help Messages

Alarm Page Online - Help for Troubleshooting

) After double-clicking failure designations, a window with


troubleshooting hints pops up !

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Indication Card

Indication Card
The indication card display common operational data of RT-flex engine.

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Indic- Card, Miscellaneous & Speed

Miscellaneous
The current estimated power is indicated.

Engine speed (n)


The actual engine speed from Crank Angle Sensors is indicated.

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Indic- Card, Fuel command (LI)

Used for Injection


The real fuel command, corresponds with the fuel command from the PCS,
except if Manual Control is used or if the WECS Fuel Command Limiter is
active.

Fuel Command PCS


The un-scaled fuel command received from the PCS (Speed Governor) via
databus.

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Indic- Card, Fuel command (LI)

WECS Fuel Command Limiter


Normal : As long as the fuel pumps have enough rack stroke to regulate
the fuel rail pressure.
Limited : If the fuel pump racks are at full delivery position and fuel
command is further increased, the fuel supply to the common rail
can not follow up. To prevent low rail pressure, the WECS Fuel
Cmd Limiter reduces the Used fuel command to the max.
possible value with stable rail pressure and max. fuel supply.

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Indic- Card, Fuel Rail Pressure

Fuel Rail Pressure


The pressure Setpoint defined by WECS SW for the actual load-point.
The Actuator output in percentage of the available fuel rack stroke.
Above 94% stroke the WECS Fuel Cmd Limiter gets activated, if the fuel
pressure breaks down.

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Indic- Card, Servo Oil Pressure

Servo Oil Pressure


The pressure Setpoint reference defined by WECS SW for the actual
load-point.

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Indic- Card, Injection Timing

Fuel Injection Timing


VIT shows the variable injection timing offset depending on the engine
speed, charge air pressure and fuel rail pressure.
VIT + FQS shows the sum of the offsets for above VIT angle value plus fuel
quality setting FQS.
Injection begin shows the sum of offsets for above VIT+FQS angle value
plus Standard Injection Begin angle value.

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Indic- Card, Number of inj. Nozzles

Working Nozzles
Number of inj. nozzles displays how many fuel injectors are currently
operating per cylinder unit.

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Indic- Card, Exhaust Valve

Exhaust Opening / Closing angle


The Exhaust Valve data displayed shows the Opening angle and the
Closing angle according to the current speed / load of engine.

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Overview Card

Overview Card
The overview card contains the most important data from the indication card
plus a few additional indications which are explained below.

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Overview Card, Manoeuvring Order

The Manoeuvring Orders show the engine


commands currently received across the databus from the propulsion control system.

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Overview Card, WECS Failures

WECS Failures shows the different alarm


groups and if there are any active faults
transmitted from FCM 3 and FCM 4 to the
alarm monitoring system.
NOTE: Engines equipped with alarm
monitoring system.
Kongsberg Datachief C20 do not use this
transmission.
They receive alarm data directly across databusses to the propulsion control system.
(CANopen bus through FCM 1 & FCM 2)

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Injection Card

Injection Card
The amount of injected fuel is measured by the fuel quantity sensor in the ICU.
Each injection measurement starts at a return value and ends at a injection
value corresponding to the given fuel command.
The Injection begin dead time between sending a WECS-9520 command and the
real injection begin is shown in the next column.
Injection begin angle indicates the actual crank angle at injection begin and the
duration time of the injection is shown in the next column.
In the On Time Open / Close columns, flexView indicates the switch time that it
takes to switch the rail valves over from one state to the opposite state. Times
above 3,0 ms generally point out a rail valve failure.
These indications help troubleshooting normal and static injection system failures.
For dynamic failures, the injection curve trend gives more detailed feedback.

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Injection Card

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Exhaust Valve Card

Exhaust Valve Card


The Open Pos. & Close Pos. Sensor columns show the valve stroke as a mA signal.
A higher value indicates an open valve in the left columns, whereas a lower value
indicates a closed valve in the right columns of this card section.
The Deadtime between WECS-9520 command and specific stroke of the spindle is
indicated in the columns for each valve and movement (open/close).
The On Time Open / Close columns indicates the switch time that it used to switch
the rail valves over from one state to the opposite state. Times above 3,0 ms
generally point out a rail valve failure.
These indications help troubleshooting normal and static exhaust valve system
failures. For dynamic exhaust valve failures, the exhaust valve curve trends give
more detailed feedback.

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Exhaust Valve Card

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Change Command Fields

First push the Shift key and keep it depressed.


Then (Shift key still depressed) press Arrow up or Arrow down keys to
have a choice option indicated in the selected field. The option will be shown with
a yellow background.
By pressing Shift and Enter, the selected option is activated for the engine
control and the background colour of the field changes back to white.

Click in field

&

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User Card

User Card
The user card allows setting FQS, selecting VIT- and Heavy Sea Mode,
Common start valve test modes and switching injection cut offs on separately
selectable cylinders.
Further Injection venting and Exhaust valve manual test commands can be
selected.

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User Card, VIT + FQS

VIT + FQS
The VIT fields allow changes of the
following settings:
Altering the Fuel Quality Setting FQS
within a range of +/- 3,0< crank angle.
Switching off the VIT function, e.g. for running-in of new components.
OPTION: If engine is delivered with Low NOx mode, this function can be
switched on and off in the VIT + FQS section. The Low NOx activates a
different tuning mode to obtain minimum NOx output at reduced firing
pressure.

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User Card, Common Start Valves

Common Start Valves


This function allows separate testing of the two parallel acting solenoid valves
for the automatic start air valve.
With the next start, slow turning or air run the automatic start valve will be
controlled only by the enabled solenoid valve only. When starting air release is
stopped again, the field automatically triggers back to enabled condition.

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User Card, Heavy Sea Mode

Heavy Sea Mode


The heavy sea mode changes certain functions in the WECS-9520 to allow a
safe and stable engine operation during extremely rough weather and avoids
possible failing of a cylinder unit, if a single injector fails.
The common rail fuel pressure will be set to a fixed value of 700 bar.
All injectors are used for fuel injection over the entire load range.

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User Card, Injection cut off

Injection cut off


The injection on single cylinder units can be cut off with these fields.
WECS-9520 automatically triggers a slowdown to prevent engine overload.
The exhaust valve will remain in operation while the injection is cut off.

CAUTION:
If more than 1 cylinder is cut off, engine
vibrations can lead to dangerous resonance
condition due to misfiring. Make sure speed is
reduced sufficiently to prevent high torsional
vibrations. If possible avoid switching off firingorder consecutive cylinders.

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User Card, Injection Venting

Injection Venting
This function allows a venting of the injector pipes and ICUs. It can be
selected to vent all or separate units. The function is blocked if the fuel rail
pressure is still higher than the injector needle opening pressure.
After selection, the venting process continues
for 30 seconds, then the fields automatically
revert to OFF condition, until selected again.

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User Card, Exhaust Valve Auto. / Manual

Exhaust Valve Automatic / Manual CMDs


This function allows separate testing of exhaust valves during engine at
standstill with reduced pressure from the control oil pumps.

AUTO

Normal condition, valve closed


at engine standstill

MAN. OPEN

Valve opens

MAN. CLOSE Valve closes


TURN. GEAR Valve opens while crankshaft is
turned through

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Adjust Card

Adjust Card (password protected)


The Adjust page allows changing miscellaneous parameters like artificially
optimize injection timing for ICUs with disconnected FQ sensors and it allows
to modify the injection timing and the exhaust valve closing within a certain
range for balancing the cylinder loads.

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Adjust Card

Access to Adjust Parameters


Login Adjust

For any parameter access a login menu pops up when


you try to change a value with Shift and Arrow up or
Arrow down keys. The password is flexView after
clicking ok all parameters become accessible for changes.
The Adjust level automatically switches back to normal
user level 15 minutes after the last parameter change.

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Adjust Card, Slow Turning & Aux. Blower

Slow Turning & Aux. Blower Settings


Slow turning trigger pulse time and the period time are set with these
parameters. Standard setting is a pulse of 0.10s per each second for the
starting pilot valves on the cylinder covers.
The auxiliary blowers start and cut off levels are set in the lower fields.

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Adjust Card, CA Sensor

CA Sensor Offset
With cylinder #1 at TDC, the CA-sensors should indicate 0.0< in the fields
Crank angle 1/2.
If required, any indicated offset can be entered in the upper CA 1/2 Offset
field, the corrected crank angle indication will change to 0.0<.

CAUTION:
Wrong adjustment can cause a
WECS critical failure and shut
down the engine immediately!

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Adjust Card, TDC Offset

TDC Offset
The TDC angle is measured with a pickup from a target on the flywheel. When
the engine is at standstill or turned with the turning gear, TDC indication
changes from Gap to Tooth while the target is passing the pickup.
The Measured TDC Angle is only updated when the engine is running! This
angle shifts to a higher value in dependence of the engine speed. The offset is
adjusted to 0.0 < at approximately the middle of the engines speed range,
therefore it is not zero at engine standstill !

CAUTION:
Wrong adjustment can cause a
WECS critical failure and shut
down the engine immediately!

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Artificial Injection Quantity Feedback Tuning

Artificial Injection Quantity Feedback Tuning


If a defective fuel quantity sensor is disconnected from an ICU, the WECS9520 uses an artificial fuel quantity feedback ramp instead of the sensor
signal. This ramp gives an artificially rising mA feedback, whose fixed
steepness (=injected fuel per ms) can be different from the real injection. The
ramps length corresponds to the actual fuel command from the governor /
MCP.
WECS now uses an injection-time control instead of the normal volumetric
control. With a same fuel command the real injection time gets shorter, the
steeper the angle of this ramp is set. This can lead to some load- and exhaust
gas temp. deviation between the normal cylinders and the one(s) working with
this emergency setting.

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Artificial Injection Quantity Feedback Tuning

The artificial injection quantity FB Tuning allows setting this steepness of the
ICU Emergency Feedback and balancing the cylinder load during this
operational mode.
The higher the [%/ms] parameter is set, the faster the faked virtual fuel qty.
sensor moves and the earlier the injection cycle is terminated. => Less
cylinder power.
Also the real injection begin angle cannot be measured in this emergency
mode. But the artificial deadtime allows a shifting of this angle, relative to the
injection command given by the WECS.
The higher the artificial deadtime [ms] parameter is set, the earlier WECS
triggers the injection command. => Higher firing pressure, lower exhaust gas
temperature.

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Adjust Card, Exhaust Valve Closing Offset

Exhaust Valve Closing Offset


These fields allow the user to balance the cylinder compression by advancing
or retarding the exhaust valve closing angle of separate cylinder units in a
range of:
3.0< (later closing, less compression)
down to
-3.0< (earlier closing, higher compression).

Note: The average must remain in range of +/- 0.5 <


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Adjust Card, Injection Begin Offset

Injection Begin Offset


These fields allow the user to balance the cylinder load between separate
units by advancing or retarding single injection begin angles in a range of:
1.5< (later injection, less combustion
pressure)
-1.5< (earlier injection, higher
combustion pressure).

Note: The average must remain in range of +/- 0.2 <


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Adjust Card, Injection Correction Factor

Injection Correction Factor


These user fields allow adapting the cylinder load on individual cylinder units
down to 80% of the actual fuel command.
This function can be used for running-in new liners/piston rings or if there is
any operational trouble on a specific cylinder.
Cylinder units with too low firing pressure can be adapted to get a slightly
larger fuel command share, thus on single units the value can be increased
up to 110%.

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Adjust Card

CAUTION:
Wrong adjustment can lead to cylinder overpressure and
consequent damage of liner and piston rings.
Any parameter change should be done in small steps and
proper pmax and injection timing have to be verified on the
affected cylinder units with hand drawn pressure diagrams
if no cylinder monitoring system is installed !

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LUB Cards

LUB Cards
The LUB card contains the user parameters to adjust the lubrication feed
rate, to initiate manual lubrication and to monitor ALM status and amount of
lubrication oil pulses within a selectable time range.

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LUB Cards, Feed Rate

Feed Rate
In these fields the feed rate can be set for each cylinder
unit. The values can be adjusted between 0.6 g/kWh
and 1.6 g/kWh.
Different lubrication feed rates at different cylinder units
cause a drop down menu to appear at the bottom field
Set to all. This Set to all field allows to (re-)set
different cylinder unit feed rates to a common value.
Note: Set cursor to a character of the text Set to all
and press F1 to call up a brief help menu on MultiTarget-Scalars.
To set all values to an equal value open the dropdown
menu and select the corresponding value.
Then press Enter.
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LUB Cards, Feed Rate

The selected value is shown with a blue background.


The indicated value can now be changed by using
Shift and Arrow up or Arrow down keys
(e.g. to 1.25 g/kWh).
With Shift and Enter all values are set to
selected value

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LUB Cards, Manual Lubrication

Manual Lubrication
In the upper field a single cylinder unit can be selected for manual
lubrication.
The number of pulses is adjustable in the lower filed.

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LUB Cards, Pulse Counters

Pulse counters
The number of counted pulses is indicated per cylinder unit in the No. of
Command column.
The measured peak pressure of the injected lubrication oil is indicated in the
column Peak Pressure.
The counter restarts again after the time selected in the field Timer for
Memory.
The counter can be reset to zero by changing the Reset Counter field from
ready to reset.

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LUB Cards, Pulse Counters

There are two options in Selected: field for the pulse counters:
Memory: This selection updated the indicated number of pulses only
after the adjusted time for memory has elapsed and updates again only
after next passing of the adjusted time.
Counter: This selection continuously counts up the pulses until the
memory timer has elapsed. Then it starts again from zero.

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LUB Cards, ALM Status

ALM Status Indication

This column shows the state of the lubrication module


on the separate cylinder units.
The different indications are:
OK
Unit in normal operation
Download
FCM downloads software into ALM
Failure
No communication to the ALM module
???
No data available

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LUB-Par Card

LUB-Par Card
This card shows detailed pulse lubrication parameter-settings and indicates the ALM
Deadtimes. Further lubrication share rates are indicated in the columns Into/Below.
The difference of these fields to 100% is the share for above (i.e. in below picture
60%). This information might be useful for any feedback to Wrtsil service or
customer support.

Note: Blue colour values are indications


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SW-Info Card

SW-Info Card
This card indicates detailed information on the software currently installed in the
WECS FCM-20 modules on the engine. This information might be useful for any
feedback to Wrtsil service or customer support.

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View Menu

View Menu
In the View Menu, different trend menus for monitoring the RT-flex common
rail system and two special fast trends to record the performances of the
exhaust valve drive system and of the injection system including the injection
control unit ICU can be select.

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View Menu, Open Trend

Open Trend Menu


The Open Trend menu offers 3 different standard trends.
1. Performance
2. Crank Angle Sensors
3. Analogue Indications

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View Menu, Open Trend

Show shape indicates separate data points as dots on the measuring curves.
Update time defines how often the screen data-points are updated.
Max = All other flexView cards will be frozen, data exchange between WECS-9520
and fV is used only for trend-data Visible time range defines the visible time frame
on the trend screen.
High = All received values are indicated.

Visible Time Range changes the


timescale.
Trend time range defines the time
frame that will be stored in the flexView
database. After this time has elapsed,
the latest data of the time range length
remains stored, when a trend is saved.
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View Menu, Exhaust Valve Curve

Exhaust Valve Curve


The exhaust valve curve records precise trends from single opening or
closing strokes of individual exhaust valves.
These functions help to detect erratic performance of single units. Each
trend is triggered by the corresponding WECS-9520 command.
Curves from different cylinders can be recorded together to verify
suspicious behaviour with normally performing exhaust valves.

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View Menu, Exhaust Valve Curve

Open trend curve


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View Menu, Exhaust Valve Curve

Close trend curve


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View Menu, Injection Curve

The Injection Curve


The injection valve curve records precise trends of individual ICUs. This
function helps to detect erratic performance of single units.
Each trend is triggered by the corresponding WECS command.
Curves from different cylinders can be recorded together to verify
suspicious behaviour with normal performing ICUs.
At high engine load the screen shows only the important part of the curves.

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View Menu, Injection Curve

All ICU measuring curves at very low engine load.


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View Menu, Injection Curve

Begin dead time and the injection stroke of the ICUs


quantity piston feedbacks.
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