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Diesel Systems Common Rail Systems CRSN3 with 2,000 to 2,500 bar

CRSN3-20, -22, -25

Rail-pressure sensor System variants: Rail 2,200 bar PLV 2,500 bar PCVN Sensors Pre-lter* Highpressure pump EDC High pressure Tank Low pressure Solenoid injector Actuators

In addition to emissions legislation, fuel consumption and specic engine performance are the main drivers behind the further development of commercial-vehicle engines. Combined with the SCR catalytic converters which have become the prime source for achieving Euro VI emission standards, Tier 4, US10 or IMO 3 the high injection pressures also provide advantages in fuel consumption. Only a one-percent reduction in fuel consumption helps to save 500800 euros in annual operations costs. For this reason, we are upgrading the Common Rail System CRSN3 series. The CRSN3-18 (1,800 bar) system was successfully launched for series produc-


* Water separator on lter or pre-lter

Customer benets Increases fuel eciency and subsequently reduces CO2 output Contributes towards achieving Euro VI, US10, Tier 4, JPNLT and IMO 3 emission limits High torque and eciency at low engine speeds High hydraulic system eciency and reduced energy consumption Easy integration into existing and future engine platforms Advanced diagnostics potential with the integration of a pressure control valve

tion in 2005. Since 2010, the follow-up CRSN3-20 (2,000 bar) and CRSN3-22 (2,200 bar) generations have been available. The CRSN3-25 with a system pressure of 2,500 bar is scheduled to start series production in 2013. Possible applications CRSN3 systems are intended for use in medium- and heavy-duty as well as for o-highway and marine applications. They cover a wide range of engines of up to 16 cylinders. Operating principle Starting at 2,000 bar, the CRSN3 systems achieve a higher systems eciency through their new injector concept, thus reducing fuel consumption. Inside the injector, the parts up to the control valve are charged with the rail pressure. This avoids a constant fuel ow between the high- and low-pressure area. Only while the solenoid is triggered, the valve opens and a small control quantity is fed into the fuel return line. In order to permit the opening and closing of the nozzle needle in this pressure-balanced internal injector volume, the needle is hydraulically coupled to the push rod. Optimized injector-fuel maps allow for quantity correction throughout the useful lifetime of the entire system through the aid of software learning functions.

Diesel Systems | Common Rail Systems CRSN3 with 2,000 to 2,500 bar and no-leakage injectors Technical features
System pressure Max. number of injections 2502,500 bar 7

System design (typical conguration) Three types of high-pressure pumps are available for various engine sizes and applications. The CP4 highpressure pump is suitable for medium-duty applications with a system pressure of up to 2,500 bar. The CPN5-22/2 high-pressure pump covers the heavyduty requirements of up to 2,200 bar system pressure. It is based on in-line pump technology and includes a newly developed internal pre-supply gear pump. A further development of this pump will reach higher emission targets and achieve fuel-consumption benets with pressures of up to 2,500 bar. This pump is very compact, robust and lightweight. Alternatively up to 2,000 bar can be generated by a PF 45-20 camshaftless pump which is driven by the engine camshaft. The forged high-pressure rail (HFRN) is tted with drilled throttles, a rail-pressure sensor and a pressurelimiting valve (PLV) for applications up to 2,200 bar. Instead of the PLV, the 2,500 bar CRSN3-25 system is equipped with a pressure-control valve (PCVN). This

Hydraulic ow rate CRSN3-20, -22 4001,300 cm3/30 s CRSN3-25 4001,000 cm3/30 s Operating voltage Lifetime Medium-duty sector (MD): Heavy-duty sector (HD): Fields of application Engine power/displacement Emission targets 12 V/24 V 750,000 km (on-highway) 10,000 h (o-highway) 1.6 million km (on-highway) 15,000 h (o-highway) MD, HD, OHW, marine 2035 kW/l Euro VI, US10, Tier 4, JPNLT, IMO 3

Max. number of cylinders 16

System components of the CRSN3-20, -22

ensures extended pressure reduction functionality as well as enhanced diagnostic functionality with active pressure control. The CRIN3 injector with 2,000 to 2,500 bar is the heart

of the system. It is compatible in installation with previous generations as its outer dimensions have been retained unchanged. All system functions are controlled and monitored by the EDC17 Electronic Diesel Control. The EDC17 platform has advanced monitoring and safety functions such as limp-home functionality, Outlook

1 CP4-20/2-MD/OHW high-pressure pump*

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CPN5-22/2 high-pressure pump* PF45-20 camshaftless pump* HFRN-20, -22 high-pressure rail with PLV5-22 CRIN3-20, -22 injector EDC17CV control unit *alternative variants

System components of the CRSN3-25

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Bosch engineers are already engaged in the further evolutionary development of this modular system. Future generations of the CRSN3 platform will use this strong foundation for system pressures over 2,500 bar.

Robert Bosch GmbH Diesel Systems Postfach 30 02 20 70442 Stuttgart Germany Printed in Germany 292000P0WJ-C/CCA-201302-En

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CP4-25/2-MD/OHW high-pressure pump* CPN5-25/2 high-pressure pump* HFRN-25 high-pressure rail with PCVN2-25 CRIN3-25 injector EDC17 CV control unit *alternative variants

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