TECHNICAL

BULLETIN

Wärtsilä El & Automation AUTMT254GB

Technical Services Issue 4, 03.05.2018

Opportunity to upgrade Wärtsilä

Frequency Converters with
Next opportunity
Cooling Flow Monitoring System
Information to all Owners and Operators of Concerned products/components
Wärtsilä Frequency Converters. This technical bulletin concerns all
Wärtsilä Frequency Converter (WFC).
Product Reference type: Reference
Detailed description regarding the
WFC monitoring of cooling water flow.
PD_ARLVFC Problems
PD_MDLVFC The physical damage in power modules
PD_PRLVFC due to the lack of effective cooling water
flow through diode and power module.
Solution
The use of cooling flow monitoring system
to alarm the absence of required flow
amount. The flow sensor also monitor
water temperature.
Validity / Issue
Until further notice.
Before taking any action, always check the
available on line systems for the latest
revision of this document. Any locally
stored or printed version is considered to
be an uncontrolled document.

Wärtsilä Norway AS Tel (24h): +47 53 42 25 00

5420 RUBBESTADNESET Fax: +47 53 42 25 01
Norway www.wartsila.com
 TECHNICAL BULLETIN

AUTMT254GB, Issue 4, Page 2 / 8

Document history
Issue Date Description SBWT ID
1 02-07-2016 Initial release
2 09-11-2015 Changed issue date (wrong date in issue 1, 1083
02.07.2016)
3 10-11-2017 Upgraded document according to new sensor 2271
type.
4 03-05-2018 Added installation instruction chp 4 2523

Contents
Page
Document history 2
1 Introduction 2
2 Problem definition 3
3 Solution 4
4 Implementation 5
5 Material list 8
6 Contacts 8

1 Introduction
Wärtsilä has delivered Power Modules, as a part of Frequency Converter deliveries
over the last 12 years. While the reliability of the Power Modules have been excellent
overall, occasionally a Power Module will need service. One scenario where service is
required occurs when the cooling water flow requirement is not met. Wärtsilä has
developed a solution to monitor the cooling water flow to the Wärtsilä Frequency
Converters individual cabinets. This is to meet new requirements from existing
customers.

Both rectifier modules and power modules can overheat when cooling water flow is
reduced. This can be caused by clogged strainers or other reasons. Strainers can be
clogged suddenly or gradually over time, and this may go undetected by the ship’s
monitoring system (IAS). Overheating of the modules may result in damages, loss of
time and money or even cause a short circuit in the module. The solution presented in
this bulletin makes the cooling water flow visible to the operator, and adds an alarm to
the IAS system that triggers when an anomaly is detected.
 TECHNICAL BULLETIN

AUTMT254GB, Issue 4, Page 3 / 8

Wärtsilä recommends this upgrade for all installations. This cooling flow monitoring
system offers two types of solutions:

• Monitoring of rectifier modules only.

• Monitoring of all frequency converter cubicles.

The first option provides added security for currently installed systems. Monitoring of all
frequency converter cubicles can also predict issues prior to starting a critical or full
power operation.

2 Problem definition
Wärtsilä Variable Speed Drives are water cooled and connected directly to the
installation’s LT Fresh water cooling system. The ship’s cooling system is monitored,
but only at system level. The Wärtsilä frequency converters monitors temperature on
the most critical components internally, but depends on equal flow in each cabinet.

Table 1: Total required water flow PR VSD

Build size Modules (l/min) Air cooling (l/min) Total (l/min) Total (m³/h)
800kW 25+25 10 60 3,6
1500kW 50+25 10 85 5,1
2700kW 2*50+25 2*10 145 8,7
3800kW 3*50+2*25 3*10 230 13,8
5000kW 4*50+2*25 4*10 290 17,4

A high number of installations are designed with individual strainers for each cubicle,
and there have been cases where these have clogged. To enable vessel operators to
have better control of the cooling system, Wärtsilä has developed a flow monitoring
setup, with overview and alarms included in the Wärtsilä IAS system.

Water flow monitoring provides vessel operators and service engineers a good
indication if complications occur with cooling of the drive. Quality of cooling water
varies from installation to installation; it is then useful to detect reduced water flow in
the drives, as this can be a result of blocked strainers due to particles in the cooling
water. Other causes for reduced cooling water flow may exist. Being able to detect
cooling water issues may save power/rectifier modules, as early warning of possible
overheating errors gives alarm. With measurement and alarm at each cubicle it is also
possible to avoid starting heavy/critical operations if the cooling water flow is low. A
water flow detection system is therefore highly recommended, since the investment
cost is very low compared to the damage that can occur if sufficient cooling water flow
is not maintained.
 TECHNICAL BULLETIN

AUTMT254GB, Issue 4, Page 4 / 8

Figure 1: Cooling water inlet/outlet on the bottom of the drives

3 Solution
Wärtsilä has chosen a solution to install a flow sensor to each of the cooling loops of
the cabinets. The sensors must be located on the inlet pipes of the drive, between
valve and strainer. It is recommended to have valve before and after the strainer/flow
sensor due to maintenance. With the sensor mounted on the inlet, we have control of
the inlet water temperature as well. The signals are relayed to Wärtsilä IAS, and will
give an alarm for the given cabinet if the deviation exceeds the limits. There is no
forced trip, nor any start interlock, but these can be arranged with redundant sensors.

Solution involves installing flow sensor (SM8000). This sensor is connected to the PLC
by means of additional wiring and an extra WAGO I/O (750-657) that reads flow and
temperature from the sensor. Wires shall be fixed with the use of plastic strips.

Existing PLC program is changed so that the additional WAGO IO-Link card is
recognized and that the physical signal is to be analyzed and IAS will be notified in
case of too low or no water flow. Flow and temperatures are sent to IAS for logging,
and can be displayed on screen.

Figure 2: Flow sensor from IFM and WAGO IO-Link card.

 TECHNICAL BULLETIN

AUTMT254GB, Issue 4, Page 5 / 8

Figure 3: VSD cooling system on 5,0MW PR

Figure 3 illustrates VSD cooling system on a 5 MW passive rectifier. Outermost

sections include diode modules which in the case of clogged tubes might have reduced
cooling effect. Overheating can either cause failures on diodes or melting of the cooling
tubes of the modules.
There are often several valves already installed on the cooling system (drawn by grey
on Figure 3). These are used to regulate the flow in the converter. Note that cooling
system can vary from installation to installation and may not always have the same
setup.

4 Implementation
The following hardware are required for this implementation, and are included in the
package sold by Wärtsilä:
• Flow sensor
• Needed PLC module(s)
• Terminal blocks and connections for the control cabinet
• Updated PLC program and el-schematics of the solution.
• EMC roxtech cable gland RM20BG is included.
Wärtsilä service engineers perform the needed configuration. However, the yard
installs the sensor, additional house and adapters. A Wärtsilä engineer performs the
changes to the Integrated Automation System (IAS) on site.
Installation/vessel with other IAS supplier than Wartsila, need to involve this supplier for
implementation of new signals and mimic on screens.

NOTE:
Engineering and software update is not included in the material list.
 TECHNICAL BULLETIN

AUTMT254GB, Issue 4, Page 6 / 8

4.1 Recommended installation position.

• Install the unit so that the measuring pipe is always completely filled.
• Arrange for inlet and outlet pipe lengths. Disturbances caused by bends, valves,
reductions, etc. are compensated for. It applies in particular: no shut-off and control
devices are allowed directly in front of the unit.

D: pipe diameter S: disturbance (e.g. shut-off / control

F: direction of flow device, pump, bends)
Figure 4:

4.2 Not recommended inatllation position

Avoid the following installation positions:

F: flow direction

Figure 5:
 TECHNICAL BULLETIN

AUTMT254GB, Issue 4, Page 7 / 8

F: flow direction

Figure 6:

4.3 Installation in pipes

The units with a G thread can be installed in the pipes using adapters. Information
about the available mounting accessories at www.ifm.com. A correct fit of the unit and
ingress resistance of the connection are only ensured using ifm adapters.

Figure 7:
 TECHNICAL BULLETIN

AUTMT254GB, Issue 4, Page 8 / 8

1. Grease the threads of the process connection, adapter and sensor. Use a ubricating
paste which is suitable and approved for the application.
2. Screw the adapter (B) into the pipe (A).
3. Place the seals (C) and install the unit according to the marked flow direction.
4. Screw the adapter (B) with the threads (D) until it is hand-tight.
5. Tighten the two adapters in opposite direction: Tightening torque: SM6/SM7/SM8 =
30 Nm; SM4 = 15 Nm.

After installation air bubbles in the system can affect the measurement.
Corrective measures: Rinse the system after installation for ventilation.

5 Material list
Table 2: Order numbers

Material no. Material description

PAAF482694 Retrofit flow sensor package with temp measurement for single cabinet
PAAF482711 Retrofit flow sensor package with temp measurement for double cabinet
PAAF482713 Retrofit flow sensor package with temp measurement for triple cabinet
PAAF482736 Retrofit flow sensor package with temp measurement for quadruple cabinet

6 Contacts
6.1 How to contact Wärtsilä
For questions about the content of this Instructions bulletin, or if you need Wärtsilä
assistance, services, spare parts and/or tools, please contact your nearest Wärtsilä
representative.
If you don’t have the contact details at hand, please follow the link “Contact us” – “24h
Services” on the Wärtsilä webpage:
www.wartsila.com

6.2 Contact Local Sales Support

All information regarding the need of cooling flow monitoring system should be
provided through the local Wärtsilä Services support contact who will coordinate with
the Services contact in Wärtsilä Norway.

© 2018 Wärtsilä Norway AS – All rights reserved

No part of this publication may be reproduced or copied in any form or by any means (electronic, mechanical, graphic, photocopying,
recording, taping or other information retrieval systems) without the prior written permission of the copyright holder. Wärtsilä Norway AS
makes no representation, warranty (express or implied) in this publication and assumes no responsibility for the correctness, errors or
omissions for information contained herein. Information in this publication is subject to change without notice.

Unless otherwise expressly set forth, no recommendation contained in this document or any of its appendices is to be construed as
provided due to a defect of the product, but merely as an improvement of the product and/or the maintenance procedures relating thereto.
Any actions by the owner/operator as a result of the recommendations are not covered under any warranty provided by Wärtsilä and such
actions will thus be at the owners/operators own cost and expense.

NO LIABILITY WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL, IS ASSUMED WITH RESPECT TO
THE INFORMATION CONTAINED HEREIN. THIS PUBLICATION IS CONFIDENTIAL AND INTENDED FOR INFORMATION
PURPOSES ONLY.