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Diesel Systems
Common Rail Systems CRSN3
with 2,000 to 2,500 bar
In addition to emissions legislation, fuel consumption
CRSN3-20, -22, -25
Rail-pressure
sensor
Filter*
System
variants:
Rail
≤ 2,200 bar
PLV
2,500 bar
PCVN
Sensors
Actuators
Tank
Low pressure
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 –
fuel consumption. Only a one-percent reduction in fuel
EDC
High pressure
behind the further development of commercial-vehicle
the high injection pressures also provide advantages in
Pre-filter*
Highpressure
pump
and specific engine performance are the main drivers
consumption helps to save 500 – 800 euros in annual
Solenoid
injector
* Water separator on filter or pre-filter
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-
Customer benefits
tion in 2005. Since 2010, the follow-up CRSN3-20
Increases fuel efficiency and subsequently
(2,000 bar) and CRSN3-22 (2,200 bar) generations
reduces CO2 output
Contributes towards achieving Euro VI, US10,
Tier 4, JPNLT and IMO 3 emission limits
have been available. The CRSN3-25 with a system
pressure of 2,500 bar is scheduled to start series
production in 2013.
High torque and efficiency at low engine speeds
High hydraulic system efficiency and
reduced energy consumption
Easy integration into existing and future
engine platforms
Advanced diagnostics potential with the
Possible applications
CRSN3 systems are intended for use in medium- and
heavy-duty as well as for off-highway and marine
applications. They cover a wide range of engines
of up to 16 cylinders.
integration of a pressure control valve
Operating principle
Starting at 2,000 bar, the CRSN3 systems achieve a
higher systems efficiency 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 flow
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
System design (typical configuration)
Technical features
System pressure
250 – 2,500 bar
Three types of high-pressure pumps are available for
Max. number of injections
7
various engine sizes and applications. The CP4 high-
Hydraulic flow rate
CRSN3-20, -22
400 – 1,300 cm3/30 s
CRSN3-25
400 – 1,000 cm3/30 s
pressure pump is suitable for medium-duty applica-
Operating voltage
12 V/24 V
Lifetime
Medium-duty sector (MD): Heavy-duty sector (HD):
The CPN5-22/2 high-pressure pump covers the heavy-
750,000 km (on-highway)
12,000 h (off-highway)
1.6 million km (on-highway)
15,000 h (off-highway)
Fields of application
MD, HD, OHW, marine
tions with a system pressure of up to 2,500 bar.
duty 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
Max. number of cylinders16
benefits with pressures of up to 2,500 bar. This pump
Engine power/displacement
20 – 35 kW/l
Emission targets
Euro VI, US10, Tier 4, JPNLT,
IMO 3
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.
System components of the CRSN3-20, -22
The forged high-pressure rail (HFRN) is fitted 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
1
2
ensures extended pressure reduction functionality as
3
well as enhanced diagnostic functionality with active
pressure control.
The CRIN3 injector with 2,000 to 2,500 bar is the heart
4
5
6
of the system. It is compatible in installation with
previous generations as its outer dimensions have
1
CP4-20/1-OHW, CP4-20/2-MD/OHW,
high-pressure pump*
been retained unchanged.
2
CPN5-22/2 high-pressure pump*
3
PF45-20 camshaftless pump*
All system functions are controlled and monitored by
4
HFRN-20, -22 high-pressure rail with PLV5-22
5
CRIN3-20, -22 injector
6
EDC17CV control unit
the EDC17 Electronic Diesel Control. The EDC17
platform has advanced monitoring and safety functions
*alternative variants
such as limp-home functionality,
Outlook
Bosch engineers are already engaged in the further evo-
System components of the CRSN3-25
1
2
lutionary development of this modular system. Future
generations of the CRSN3 platform will use this strong
3
foundation for system pressures over 2,500 bar.
Robert Bosch GmbH
Diesel Systems
4
5
1
CP4-25/2-MD/OHW high-pressure pump*
2
CPN5-25/2 high-pressure pump*
3
HFRN-25 high-pressure rail with PCVN2-25
4
CRIN3-25 injector
5
EDC17 CV control unit
*alternative variants
© Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights
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70442 Stuttgart
Germany
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www.future-with-diesel.com
Printed in Germany
292000P0WJ-C/CCA-201209-En