050_RT-Flex Training FV104 Rev005

Wrtsil Land & Sea Academy Page 1 Chapter 50-084/109 Jan. 2015

RT-flex TrainingflexView 3.7.9

(WECS version 084/ 109)

for Operators

Chapter 50-084/109Rev. 3Jan. 2015

RT-flex, flexView 084 / 109


Aim of the Training

Aim of the TrainingThe trainee should understand the function of flexView and meaning of its displays

The trainee should be able to change basic parameters via flexView

The trainee should be able to create trends

The trainee should be able to transfer data for off-line analyse



Basic Information

Basic information about flexView:

flexView is the visualisation tool of WECS-9520, which runs on a standard Windows PC.

It can be started like a normal Windows program by selecting the icon on the desktop of the PC.

The PC in the ECR is connected to WECS-9520 by using a CAN to USB adapter.

It is recommended to leave the PC on and connected the all the time.

For more detailed information see the flexView Operator Manual



Requirements for flexView PC

Requirements for flexView PC:,

Software (no other software must be installed !): Windows XP English, min. SP2 (XP professional optional), Windows Vista or Windows 7WinZip extraction (recommended)Hardcopy or Printscreen program (recommended)Antivirus program (recommended)



Windows Options

Windows options:

Display properties have to be adjusted to Windows Classic style for proper display of flexView screens

It is recommended to choose English in the Regional Settings of Windows and decimal symbolmust be dot (full stop) .



SW Improvements

Differences to older SW versions:

AutoDownload function Loads automatically the currently installed WECS-9520 Software to the module, which is fitted in the E90 box.

User CardIt is now Possible to set the Actuator manually in a Position



AutoDownload

AutoDownload:The AutoDownload function is downloading automatically the currently installed software on the FCM-20 modules (E95.01 E95.xy) to the cold FCM-20 from the store, once fitted in the E-90 box

Whatever software version is loaded on the cold FCM-20, it will be compared with the others and overwritten if not the same

The status and an instruction are shown on the Indic card

As the flexView PC is connected to #0 FCM-20 flexView is not avaliable as long as there is no FCM installed or the autodowload is not compleated



Avoiding high CAN Bus traffic on M-bus#3:ECR MCP and Speed/Fuel Dial are connected to M-Bus#03, onlyflexView PC is disconnected from M-Bus#3 and connected to M-Bus#0, which is used exclusively for flexViewService Port is disconnected.

connection M-Bus-0



USB to CAN converter

The LEDs confirm the proper working of the converter

Switch for terminator resistor

New type D-sub Plug with metal enclosure



Levels of Access

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

Blue: Crew, Operator Not necessary anymore

Green: Commissioning

Red: Developer



Start-up

Start-up screen:In case the shortcut has been deleted you find the EXE

file under: C:\flexView9520\.

your computer name



Version

your computer name



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.



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.



Indication Card

Indication card

Calculated Power.

Engine Speed

Fuel command



Indication card

Rail pressure set point

Fuel oil pressure from Sensor 1 and 2 and the mean value of both is used.

In case the actuator output is reaching 94%, the WECS fuel command limiter will become active

Indication Card



Indication card

Scavenge air pressure from sensor 1 and 2, the max. value is used.

Control oil pressure (if)

Servo oil pressure from sensor 1 and 2, the mean value of both is used.

Indication Card



Indication card

Injection timing with injection variables.

Opening and closing angle of exhaust valve

Status of Software

Indication Card



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.

1 32 4 5 6

1 Type of a log message; 2 Log messages table; 3 Checkbox for Hiding restored logs; 4 Checkbox for Hiding acknowledged logs;5 Checkbox for Hiding flexView logs (only visible in Adjust mode);6 Checkbox for Hiding event logs.



flexView Log message

1 Type of log message;2 FCM-20 module that produces the message; 3 Short message description; 4 Time when message appeared in the log;5 Time when message was restored

1 5432

WECS-9520 passive failures Additional information for the WECS-9520 failures WECS-9520 cylinder unit related failures WECS-9520 Critical failures flexVeiw program related failures, record of the parameter change. Events (e.g. start/stop from Remote control, Heavy Sea mode, etc) Login information (e.g. change of access level to Adjust) WECS-9520 common failures WECS-9520 pressure related failures Cylinder lubrication system (CLU-4) related failures



Alarm Page Online - Help for Troubleshooting

) After double-clicking failure designations, a window with troubleshooting hints pops up !

Help Messages



Change Command Fields

How to access and change command fieldsCommand fields which can be altered by the user have a white background

Any selection of a command field option in the Operator flexView is done in the same way

The desired field is selected with a mouse click

To prevent any unwanted selection of a field option, it is necessary to push two keys simultaneously to select an option or to enter the selected choice into action for the engine control



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 whiteOnly fields with a white background can be changed

n& &

Click in field



Overview Card

Overview CardThis page shows, similar to the Indication Page, a good overview of the engine status.



Injection Card

The Injection begin dead time between sending an injection command (from WECS-9520) and the real injection begin is shown on 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 2,5 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



Injection Card



Exhaust Valve Card

Exhaust Valve CardThe Open Pos. & Close Pos. Sensor 1/2 columns show the valve stroke as a mAsignal. A lower value indicates an open valve in the left columns, whereas a highervalue indicates a closed valve in the right columns of this card section (RT-flex82 opposite)

The Deadtime between WECS-9520 command and begin of the opening / closing stroke is indicated in the columns for each valve and movement (open/close). This is the time delay between the command for opening / closing and the beginning of the valve stroke into the corresponding direction

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 2,5 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



Exhaust Valve Card

Exhaust Valve

Exhaust Valve Actuator with Rail Valve



User Card

User CardThe user card allows to change the value of the FQS (Fuel Quality Setting), selecting VIT (variable Injection Timing), change-over of control oil pumps (some engine types only), main start valve test modes and Heavy Sea Mode

Further, for each individual cylinder, injection can be cut off, injection venting initiated and exhaust valve manual test commands can be selected



VIT, FQS

VIT, FQSThe Fuel Quality Setting FQS can be altered within a range of +/- 3,0



Control Oil Pumps

Control Oil Pumps (96,84,60MK1, 58MK1)Manual on and off commands can be set in these fields. If a single pump is selected off while the engine is running, the second pump will start up before the first one is switched off



Common Start ValvesThis 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 will remain in the disables condition.

Common Start Valves



Heavy Sea Mode

Heavy Sea ModeThe 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.

VIT function is disabled even it still shows VIT ON



Injection cut offInjection cut off

The injection on single cylinder units can be cut off from 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 firing-order consecutive cylinders.



Injection VentingInjection Venting at engine standstill

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

Please note: Air spring pressure must be applied, control (service) pump must be running, fuel pressure has to be less than 250 bar.



Exhaust ValveExhaust Valve Automatic / Manual CMDsThis function allows separate testing of exhaust valves during engine at standstill with reduced pressure from the control (service) oil pumps.

AUTO Normal condition, valve closed at engine standstillMAN. OPEN Valve opens (check w. EXHV card as 2nd card)MAN. CLOSE Valve closesTURN. GEAR Valve opens while crankshaft is turned through



Fuel Pump Actuators Position TestA new Function has been added,As long as a Critical failure is present it is possible to move the Actuators toPos. 0%, 50% or 100% for easy checking of Fuel rack Position.To Generate a Critical failure just press Emergency Stop



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.

flexView



Slow Turning + Aux. Blower

Slow Turning & Aux. Blower Settings SlowTurningSlow turning trigger pulse time and the period time are set with these parameters. A pulse of 0.08 - 0.20s per each 0.5 2.0 seconds for the starting pilot valves on the cylinder covers.

The auxiliary blowers start and cut off levels are set in the lower fields 0.0-1.0bar.Final adjustment depends on Tuning



CA Sensor OffsetWith 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.

CA Sensor

CAUTION:Wrong adjustment of both offsets can cause a WECS critical failure and interlock engine start and operation !



TDC OffsetTDC 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 of offsets can cause a WECS critical failure and interlock engine start and operation !



Exhaust Valve ClosingExhaust Valve Closing OffsetThese 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 a range of +/- 0.5



Injection Begin OffsetInjection Begin OffsetThese 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)

down to

-1.5 (earlier injection, higher combustion pressure)Note: The average must remain in a range of +/- 0.2



Injection Correction FactorInjection Correction Factor

The cylinder load on individual cylinder units can be reduced down to 80% of the actual fuel command

This function can be used for running-in new liners/piston rings or in case of any operational trouble on a specific cylinder



Servo oil PumpServo oil Pump

The Dynex and the new Bosch Servo oil pump are controlled by a PWM Signal.

The first collumn shows the Set point the second collumn the actual currentA alarm will be released if the The current divides more than 100mA for more than30sec. from the setpoint.



Adjust Card

CAUTION:Wrong adjustment can lead to cylinder overpressure and consequentdamage of liner and piston rings.

Any parameter change should be done in small steps and proper pmaxand injection timing have to be verified on the affected cylinder unitswith hand drawn pressure diagrams if no cylinder monitoring system isinstalled !



Lub Card

Pulse Lubrication User Interface (not RPLS)If the engine is equipped with Pulse Feed Lubrication, in these fields manual lubrication to selected cylinder units and the feed rate can be set. Feed rate adjustment is done by selecting the desired cylinder unit.



Lub Card, Power Indication

The upper field indicates the estimated powerIf an external load reference from the shaft power meter is used for the lubrication system, the lower field (Power for Lubrication) will indicate measured powerIf the signal is lost, it will indicate estimated power

Power Indication (visual only with option for external load signal)




The upper field indicates the estimated powerIf an external load reference from the shaft power meter is used for the lubrication system, the lower field (Power for Lubrication) will indicate measured powerIf the signal is lost, it will indicate estimated power

Power Indication (visual only with option for external load signal)




The Dynamic lubrication functionality increases the specific oil feed rate.If the engine power rises with a speed 1%/min during the period of 180 sec.The feed rate can be adjusted from 0 % to 20 % . Recommended value is 15 %. The feed rate will go to normal after 20 min of stable engine load.

Dynamic Load Dependency




Manual LubricationIn the upper field a single cylinder unit can be selected for manual lubricationThe number of pulses for manual lubrication is adjustable in the lower field



Feed Rate adjustment

Cylinder Lubrication Feed RateIn the first column the feed rate can be set for each cylinder unit individuallyIn the second column the present feed rate is visualFeed rate can be adjustment to all Cylinder at the same time by selecting Set (to) allThe values preferably be between 0.6 g/kWh and 1.6 g/kWh as per Service bulletin 18.3, for special needs even from 0.2 g/kWh to 3.0 g/kWh



Lub-2 Card, Pulse Counters

Pulse CounterThe lubrication system sends pulses to the solenoid valves on the Dosage pump. Each pulse triggers a pump stroke and supplies a defined quantity of lubrication oil for distribution along the piston rings package. The pulses are counted in the Counter column




Pulse CountersThe number shown in the column Failed indicates how many lubricating strokes couldnot be executed (Pressure feedback below 10bar), e.g. due to BUS communication failures




Pulse CountersThe Memory column shows the total number of lubricating strokes over the selected time (Timer for Memory).

The counter can be reset to zero by changing the Reset Counter field from ready to reset



Lub Card, ALM Status Indication

ALM Status IndicationThis column shows the state of the lubrication modules on the separate cylinder units

The different indications are:OK Unit in normal operationDownload FCM downloads software into ALMFailure No communication to the ALM module??? No data available or field not updated



Lub Card, ALM Pressure Monitoring

ALM Pressure monitoring

The measured peak pressure of the injected lubrication oil is indicated in the columnPeak Pressure



LUB2 Card

Share and AngleMaximum at the up stroke of each revolution of the crankshaft the lubrication oil is injected above, into or below the piston ring package of every cylinder. Share displays the distribution rate of the lubrication pulses. Below the relative angle.



LUB-Par Card

Example: With below settings out of 100 pulses, 40 are fed above the piston ring package, 40 into the ring package and 20 below the ring package.



Software Info

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



Software Info

Plant SW-InfoShows the engine typeManufacturing NumberHull No.SW-version SW- Build. The build is actually the number which is used to identify the SWThe IMO Number of the SW which will never change.



Software Info

SW-InfoIt is not allowed to change IMO CRC Values without changing the Technical file. After

a normal SW download the IMO CRC must be same as before. If the IMO CRC is different, something went wrong during Download.



Software Info

After Derating



Software Info

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

Plant SW-Info shows the engine type, Hull No., SW-version etc.CRC Values show the status of engine parametersHW Ref and Ser. No. show the version of FCM-20s and their serial numbers



Software Info

As standard always the online spare FCM is addressed. You can select any module or all together in the drop down menu. Different values in different modules result in a drop down menu, where each FCM has its value written in a separate field.

WECS-9520 Software checkThese fields indicate detailed checksums of the different software programs used in the FCMs (and if existing, ALM units).

Selection of which FCM software information will be indicated



Software Info

PARA CRC ValuesThese fields indicate the checksum of different parameter groups.

Users can only change USER and ADJUST parameters. OK indicates that all current parameters of this group are the same

as after original software download.X indicates that one or more parameters of this group were

changed since original software download.

Selection of which FCM software information will be indicated



ECR Manual Control Card

ECR Manual Control PanelThis page can be used to check the status of the manual control panel in the engine control room.

WARNING: For safe testing use only pushbuttons on panels that are not active for engine control. Using pushbuttons of active panels might start engine or aux. blowers and cause danger to people working on the engine!



LC Manual Control Card

Local Manual Control PanelThis page can be used to check the status of the local manual control panel at the engine.

WARNING: For safe testing use only pushbuttons on panels that are not active for engine control. Using pushbuttons of active panels might start engine or aux. blowers and cause danger to people working on the engine!



View Menu

View MenuUnder the View Menu, the following can be selected:

Fast trends (curves) of exhaust valves and fuel quantity pistons movements, optionally ALM pressure curves

pre-programmed and operator created trends

Historical data overview

The option for ALM Pressure Curve is only active on Retrofit Pulse Lubrication Systems (RPLS), currently not available for WECS. Option



View Menu, Open Trend

Open Trend MenuThe Open Trend menu offers different standard trends.



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.



View Menu, Add to Trend

Creating own TrendsBy clicking the right button on the mouse in the desired fields and selecting Add to Trend, the values of these fields can be shown on a new trend screen.



Trends

Saving and recalling saved TrendsAll trends can be saved and recalled later for further investigations.

First option:Export Trend Data

Save as Trend Time Range or Visible Time Range as *.txt file

Export in MS Excel and a chart can be created



Trends

Chart created with MS Excel



Trends

Second option:Save Trend Data

Recalling trends: File Load Trend DataChoose date and Time Range



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 normal performing exhaust valves




Trend with exhaust valves opening strokes




Trend with exhaust valves closing strokes



View Menu, Injection Curve

The Injection CurveThe 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




Fuel Quantity Sensor signals at very low engine load.




Begin dead time and the injection stroke of the ICUs quantity piston feedbacks.




Example of a high ICU wear on cylinder 1



IMO-Graph Card



Low NOx Graph Card



ICC

The ICC INJ cardThe green line shows the average firing pressure

The yellow line shows the target pressure.

The pressures have been taken from the Shop test results.



ICC

The ICC EXV cardThe green line shows the average compression pressure

Like on the ICC INJ page the balancing can be switched on and off.



The ICC INDICATION cardCompression pressure and firing pressure overview

Temperatures and pressures are taken from the 4 additional PT100 and the 2 pressure transmitters.

ICC



flexAdjust

Changing Expert ParametersOperators on board have no access to Expert Parameters, necessary adjustments can be done via flexAdjustNew parameters will be distributed to the customers in a ZIP fileThe ZIP file, containing a file flexAdjust[Text].mdb and a work instruction. To execute flexAdjust, the engine has to be at standstill and flexView closed !Make a back-up of the whole flexView9520 and WECS9520 folderThe flexAdjust[Text].mdb file has to be extracted/copied in to the folder C:\flexView9520\[plant] NOT INTO A MAY EXISTING flexAdjust FOLDER



flexAdjust

Now start flexViewPlease read the instruction and the messages appearing on screen carefully ! Confirm with I AgreeA list of parameters to be changed is shownSelect Read Values Adjust ValuesIf the parameters to be changed corresponds with the ones in the instruction, execute the updateThis update can take several minutesFinish the update with ExitFlexView will now start normalyThe flexAdjust.MBD file will automaticly get atime stamp and will be moved to theflexAdjust folder



Transfer of flexView Data

flexView is recording operational data of the RT-flex Engine on the flexView PCs Hard Disk under the path C:\flexView9520\.These data can easily be transferred for off-line analysis and trouble shooting by copying them Memory stick or sending by e-mail. By using a Memory stick we recommend to copy the whole folder. In case of e-mail, at least this two files:

-####.h5-Failure.mdb

Transfer of flexView Data

Note that mdb files cannot be direct sent as attachments to an e-mail, they have to be zipped or file extension renamed to md

Documents

050_RT-Flex Training FV104 Rev005