Common Rail & EFI

Common Rail Systems for Marine Propulsion Engines

HEINZMANN Common Rail Systems enable propulsion engine manufacturers and fleet operators to leverage the benefits of common rail technology. The particular safety requirements are met both by their classified controllers and their double-walled hydraulic components. Particularly with HFO operation, reliability of HEINZMANN components is ensured thanks to a proven design and the highest manufacturing quality standards. Along with tailored monitoring and safety devices, as well as flexible interfaces, a complete engine management system is offered. As a result of the precise control, marine propulsion engines operate more smoothly with lower fuel consumption and emission levels.

EFI Controls

Product Description Documents
DARDANOS I
MVC 01-24
EFI-controller MVC01  for electronic fuel injection

EFI controller for diesel and dual-fuel propulsion engines up to 24 cylinders. Wide functionality and convenient number of I/O for optimal engine operation and monitoring.

Manual DARDANOS
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Cannot find the download! ID=1059Order Form DARDANOS I

HERMES
Redundant EFI Control System

Redundant EFI control system for speed governing complemented by engine monitoring and safety shutdown functionality. Remote control and diagnosis performed through sophisticated HMI. Featuring double independent supply from the mains with accumulator backup.

Included devices:

  • MVC 01-20 EFI Controller
  • redundant power supply
  • full package of engine sensors
  • wiring harness
  • HMI

High-Pressure Pumps

The HDP-K high-pressure pumps feature a unique crank mechanism and excel with high efficiency and long endurance.
Designed to minimize wear effects on pump elements and plungers, HDP-K high-pressure pumps guaranty efficient operation and long TBO periods.

Product Description
HDP-K3 HFO
Common Rail High Pressure Pump HDP-K3-HFO

High-pressure pump with 3 pressure elements for system pressures up to 2,200 bar. Delivery rates up to 15 l/min (1 pump) / redundant concept: up to 30 l/min (2 pumps).
Designed for heavy fuel oil operation, featuring a special two-way HFO/lube-oil sealing concept, mix oil drain and high-temperature resistant design.

HDP-K4 HFO
Common Rail High Pressure Pump HDP-K4

High-pressure pump with 4 pressure elements for system pressures up to 2,400 bar. Delivery rates up to 65 l/min (1 pump) / redundant concet: up to 130 l/min (2 pumps).
Designed for heavy fuel oil operation, featuring a special two-way HFO/lube-oil sealing concept, mix oil drain and high-temperature resistant design.

Solenoid-controlled Fuel Injectors

Thanks to their static leak free design, the ICR-DS fuel injectors reduce fuel backflow by 75% compared to conventionally designed, leakage afflicted injectors. Peak pressures were diminished by 25% through the integration of an accumulation volume (rail volume). As a result, a smooth fuel flow can be achieved, which is of highest importance especially for heavy fuel oil (HFO) operation.

Product Description
ICR-DS-300
Common-Rail-Injector ICR-DS-300
Large-sized common rail injector for propulsion engines with cylinder power up to 300 kW.
Injection pressures up to 2,200 bar, injection quantities from 50 to 4,000 mm3/shot.
Designed for heavy fuel oil operation.
ICR-DS-500
Common-Rail-Injector ICR-DS-500
Large-sized common rail injector for propulsion engines with cylinder power up to 500 kW.
Injection pressures up to 2,200 bar, injection quantities from 70 to 7,000 mm3/shot.
Designed for heavy fuel oil operation.
ICR-DS-1000
Common-Rail-Injector ICR-DS-1000

Large-sized common rail injector for propulsion engines with cylinder power up to 1,250 kW.
Injection pressures up to 2,400 bar, injection quantities from 150 to 14,000 mm3/shot.
Designed for heavy fuel oil operation, featuring

  • Cooled nozzle
  • Sealed and cooled control armature, separated from fuel line
  • Integrated accumulator volume, no rail accumulator required
  • Built-in flow limiter

Rail Pressure Limiting Valves

Product Description Documents
RPLV-1S
RPLV-2S
RPLV-2S-CAR
Common-Rail Pressure Limiting Valve RPLV

Protection of common rail equipment against overpressure: Fast acting rail pressure limiting valves that perform quick pressure drop.

RPLV-1S: Pressure limitation, temporary safety function only
Engine stop required

RPLV-2S: Pressure limitation, followed by pressure drop to holding pressure (limp-home mode)

RPLV-2S-CAR: Pressure limitation, followed by pressure drop to holding pressure (limp home mode).
Operating on preset overpressure or additionally via compressed air release.

Data Sheet RPLV Valves

Common Rail retrofit

Retrofit of Marine Engines to Common Rail

HEINZMANN offers turnkey retrofit solutions for converting conventional fuel injection systems on marine drives.
In keeping with our commitment to our customers, expressed in the motto 'everything from a single source', we offer all the necessary components and services:

Conversion kit

Service package

  • Support in calculating the return on investment
  • Design
  • System adaption
  • Installation
  • Commissioning
  • Tests
  • After-Sales Service


Achievable advantages in fuel consumption and pollutant emissions are good arguments for conversion to the HEINZMANN common rail system:

  • suitable for virtually all 4-stroke engines rated 1 MW and above
  • the conversion involves no disturbance of the engine itself
  • capable of full integration into existing engine management systems

An impressive demonstration of competence in the field of retrofitting to marine drives is provided by HEINZMANN in the current Conversion of Swedish icebreakers.

To further optimise the results of conversion to common rail technology we will be pleased to fit your engines step by step with an exhaust gas recirculation system and convert them to dual fuel operation.
This guarantees a significant reduction in fuel costs and compliance with the latest exhaust gas regulations.
Of course this technology is applicable not just to marine drives but also to all large diesel engines such as those for locomotives and power generators.

GRA Retrofit 07 2015 e

Common Rail & EFI

HEINZMANN's range of common rail includes both high-precision hydraulic key components as well as > EFI controllers.
All components are exclusively developed and manufactured in-house and ensure optimal connectivity and compatibility. Therefore, HEINZMANN solutions for sophisticated common rail technology work towards the fuel efficiency and emission reduction of combustion engines.

High-Pressure Pumps

The HDP-K series features a unique crank mechanism and excels with high efficiency and long endurance.
Their robustness makes them suitable for the demanding needs of industrial environments. Designed to minimize wear effects on pump elements and plungers, HDP-K high-pressure pumps guaranty efficient operation and long TBO periods.

Product Description Applications
HDP- K2
Common Rail High Pressure Pump HDP-K2
High-pressure pump with 2 pressure elements for system pressures up to 2,200bar. Delivery rates up to 2.5 l/min. Flanged mounted. Genset
Off-highway vehicles
HDP- K3
Common Rail High Pressure Pump HDP-K3

High-pressure pump with 3 pressure elements for system pressures up to 2,200 bar. Delivery rates up to 15 l/min (1 pump) / redundant concept: up to 30 l/min (2 pumps). Flange or socket mounting.

Genset
Marine
Rail Traction
HDP-K3 HFO
Common Rail High Pressure Pump HDP-K3-HFO

High-pressure pump with 3 pressure elements for system pressures up to 2,200 bar. Delivery rates up to 15 l/min (1 pump) / redundant concept: up to 30 l/min (2 pumps).
Designed for heavy fuel oil operation, featuring a special two-way HFO/lube-oil sealing concept, mix oil drain and high-temperature resistant design.

Marine
HDP-K4 HFO
Common Rail High Pressure Pump HDP-K4

High-pressure pump with 4 pressure elements for system pressures up to 2,400 bar. Delivery rates up to 65 l/min (1 pump) / redundant concet: up to 130 l/min (2 pumps).
Designed for heavy fuel oil operation, featuring a special two-way HFO/lube-oil sealing concept, mix oil drain and high-temperature resistant design.

Genset
Marine
Rail Traction

Solenoid-controlled Fuel Injectors

The new ICR-DS fuel injector generation features a static leak free design. Fuel backflow could be reduced by 75% compared to conventional leakage afflicted common rail injector designs. Furthermore, peak pressures inside ICR-DS injectors were diminished by 25% through the integration of an accumulation volume (rail volume). As a result, a smooth fuel flow can be achieved, which is of highest importance especially for heavy fuel oil (HFO) operation.

Product Description
ICR-DS-50
ICR-DS-50 Common-Rail-Injector
Small-sized common rail injector for engines with cylinder power up to 50 kW.
Injection pressures up to 2,000 bar, injection quantities from 2 to 200 mm3/shot.
Designed for distillate diesel fuels.
CR-DS-100
Common-Rail-Injector ICR-DS-100
Medium-sized common rail injector for engines with cylinder power up to 100 kW.
Injection pressures up to 2,200 bar, injection quantities from 10 to 500 mm3/shot.
Designed for distillate diesel fuels.
ICR-DS-200
ICR-DS-200 Common-Rail-Injector
Medium-sized common rail injector for engines with cylinder power up to 200 kW.
Injection pressures up to 2,200 bar, injection quantities from 50 to 2,200 mm3/shot.
ICR-DS-300
Common-Rail-Injector ICR-DS-300
Large-sized common rail injector for engines with cylinder power up to 300 kW.
Injection pressures up to 2,200 bar, injection quantities from 50 to 4,000 mm3/shot.
Designed for heavy fuel oil operation.
ICR-DS-500
Common-Rail-Injector ICR-DS-500
Large-sized common rail injector for engines with cylinder power up to 500 kW.
Injection pressures up to 2,200 bar, injection quantities from 70 to 7,000 mm3/shot.
Designed for heavy fuel oil operation.
ICR-DS-1000
Common-Rail-Injector ICR-DS-1000

Large-sized common rail injector for engines with cylinder power up to 1,250 kW.
Injection pressures up to 2,400 bar, injection quantities from 150 to 14,000 mm3/shot.
Designed for heavy fuel oil operation.
Features:

  • Cooled nozzle
  • Sealed and cooled control armature, separated from fuel line
  • Integrated accumulator volume, no rail accumulator required
  • Built-in flow limiter

Rail

Product Description
Rail

High-pressure accumulator, customised to engine requirements

Rail Pressure Limiting Valves

Product Description Documents
RPLV-1S
RPLV-2S
RPLV-2S-CAR
Common-Rail Pressure Limiting Valve RPLV

Protection of common rail equipment against overpressure: Fast acting rail pressure limiting valves that perform quick pressure drop.

RPLV-1S: Pressure limitation, temporary safety function only
Engine stop required

RPLV-2S: Pressure limitation, followed by pressure drop to holding pressure (limp-home mode)

RPLV-2S-CAR: Pressure limitation, followed by pressure drop to holding pressure (limp home mode).
Operating on preset overpressure or additionally via compressed air release.

Data Sheet

Nabtesco

Address: Evliya Çelebi Mah. Genc Osman Cad. Giptas San. Sitesi F Blok, No:11 Tuzla , 34944 Istanbul / Turkey
Phone: +90 532 111 OGAN
Sales Department: +90 532 056 97 87
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