CRSN3 up to 2500 bar (PDF 960.22 kB) - Bosch Automotive ...

Diesel SystemsCommon Rail Systems CRSN3with 2,000 to 2,500 barCRSN3-20, -22, -25Filter*Rail-pressuresensorRailSystemvariants:≤ 2,200 barPLVIn addition to emissions legislation, fuel consumptionand specific engine performance are the main driversbehind the further development of commercial-vehicleengines. Combined with the SCR catalytic convertersHighpressurepumpSensorsPre-filter*ActuatorsEDC2,500 barPCVN– which have become the prime source for achievingEuro VI emission standards, Tier 4, US10 or IMO 3 –the high injection pressures also provide advantages infuel consumption. Only a one-percent reduction in fuelconsumption helps to save 500 – 800 euros in annualTankHigh pressureLow pressureSolenoidinjectoroperations costs.* Water separator on filter or pre-filterCustomer benefits Increases fuel efficiency and subsequentlyreduces CO 2 output Contributes towards achieving Euro VI, US10,Tier 4, JPNLT and IMO 3 emission limits High torque and efficiency at low engine speeds High hydraulic system efficiency andreduced energy consumption Easy integration into existing and futureengine platforms Advanced diagnostics potential with theintegration of a pressure control valveFor this reason, we are upgrading the Common RailSystem CRSN3 series. The CRSN3-18 (1,800 bar)system was successfully launched for series productionin 2005. Since 2010, the follow-up CRSN3-20(2,000 bar) and CRSN3-22 (2,200 bar) generationshave been available. The CRSN3-25 with a systempressure of 2,500 bar is scheduled to start seriesproduction in 2013.Possible applicationsCRSN3 systems are intended for use in medium- andheavy-duty as well as for off-highway and marineapplications. They cover a wide range of enginesof up to 16 cylinders.Operating principleStarting at 2,000 bar, the CRSN3 systems achieve ahigher systems efficiency through their new injectorconcept, thus reducing fuel consumption. Inside theinjector, the parts up to the control valve are chargedwith the rail pressure. This avoids a constant fuel flowbetween the high- and low-pressure area. Only whilethe solenoid is triggered, the valve opens and a smallcontrol quantity is fed into the fuel return line. In orderto permit the opening and closing of the nozzle needlein this “pressure-balanced” internal injector volume,the needle is hydraulically coupled to the push rod.Optimized injector-fuel maps allow for quantity correctionthroughout the useful lifetime of the entire systemthrough the aid of software learning functions.

Diesel Systems | Common Rail Systems CRSN3 with 2,000 to 2,500 bar and no-leakage injectorsTechnical featuresSystem pressure250 – 2,500 barMax. number of injections 7Hydraulic flow rateCRSN3-20, -22400 – 1,300 cm 3 /30 sCRSN3-25400 – 1,000 cm 3 /30 sOperating voltage12 V/24 VLifetimeMedium-duty sector (MD): 750,000 km (on-highway)10,000 h (off-highway)Heavy-duty sector (HD): 1.6 million km (on-highway)15,000 h (off-highway)Fields of applicationMD, HD, OHW, marineMax. number of cylinders 16Engine power/displacement 20 – 35 kW/lEmission targetsEuro VI, US10, Tier 4, JPNLT,IMO 3System components of the CRSN3-20, -221 2 3System design (typical configuration)Three types of high-pressure pumps are available forvarious engine sizes and applications. The CP4 highpressurepump is suitable for medium-duty applicationswith a system pressure of up to 2,500 bar.The CPN5-22/2 high-pressure pump covers the heavydutyrequirements of up to 2,200 bar system pressure.It is based on in-line pump technology and includesa newly developed internal pre-supply gear pump. Afurther development of this pump will reach higheremission targets and achieve fuel-consumptionbenefits with pressures of up to 2,500 bar. This pumpis very compact, robust and lightweight. Alternativelyup to 2,000 bar can be generated by a PF 45-20camshaftless pump which is driven by the enginecamshaft.The forged high-pressure rail (HFRN) is fitted withdrilled throttles, a rail-pressure sensor and a pressurelimitingvalve (PLV) for applications up to 2,200 bar.Instead of the PLV, the 2,500 bar CRSN3-25 system isequipped with a pressure-control valve (PCVN). Thisensures extended pressure reduction functionality aswell as enhanced diagnostic functionality with activepressure control.1234564 5 6CP4-20/2-MD/OHW high-pressure pump*CPN5-22/2 high-pressure pump*PF45-20 camshaftless pump*HFRN-20, -22 high-pressure rail with PLV5-22CRIN3-20, -22 injectorEDC17CV control unit*alternative variantsThe CRIN3 injector with 2,000 to 2,500 bar is the heartof the system. It is compatible in installation withprevious generations as its outer dimensions havebeen retained unchanged.All system functions are controlled and monitored bythe EDC17 Electronic Diesel Control. The EDC17platform has advanced monitoring and safety functionssuch as limp-home functionality,System components of the CRSN3-25123OutlookBosch engineers are already engaged in the further evolutionarydevelopment of this modular system. Futuregenerations of the CRSN3 platform will use this strongfoundation for system pressures over 2,500 bar.Robert Bosch GmbHDiesel Systems1234545CP4-25/2-MD/OHW high-pressure pump*CPN5-25/2 high-pressure pump*HFRN-25 high-pressure rail with PCVN2-25CRIN3-25 injectorEDC17 CV control unit*alternative variantsPostfach 30 02 2070442 StuttgartGermanydiesel@bosch.comwww.future-with-diesel.comPrinted in Germany292000P0WJ-C/CCA-201302-En© Robert Bosch GmbH 2013. All rights reserved, also regarding any disposal, exploitation, reproduction,editing, distribution, as well as in the event of applications for industrial property rights