PC Program High-Pressure Pump

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ODYSSEUS

Complete Common Rail Systems

Engine & Turbine Management

Rail

PC Program High-Pressure Pump

Control Unit

 System pressure up to 2000 bar

 Various sizes of injectors and pumps

 All components from one supplier

 Applicable for diesel fuels and heavy fuel oil

Injectors

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ODYSSEUS

Common Rail (CR)

HEINZMANN offers the ODYSSEUS Common Rail Fuel Injection System including

complete fuel injection equipment (HP pumps, injectors, accumulators, HP piping, safety valves, etc.) for different engine sizes, applications and fuel qualities.

The product range of HEINZMANN hydraulic high-pressure components covers the following engine power outputs:

1. ODYSSEUS “S” for engines up to 130 kW 2. ODYSSEUS “M” for engines up to 560 kW 3. ODYSSEUS “L” for engines up to 1.500 kW 4. ODYSSEUS “XL” for engines up to 10.000 kW 5. ODYSSEUS “MP” Micro Pilot Common Rail

Fuel Injection System for gas engines HEINZMANN has more than 100 years of experience with speed governing of industrial engines. Today our digital engine management systems DARDANOS include all aspects of the present state of engine control, monitoring and diagnosis. They meet the international requirements of classification societies such as German Lloyd, Lloyd’s Register, ABS and DNV. HEINZMANN solves all customer needs with regards to instrumentation, cable harness design and adaptation as well as commissioning and worldwide customer care.

The ultra-high precision ODYSSEUS hydro-mechanical components and the sophisticated engine management systems DARDANOS forge an integrated and complete solution for modern fuel injection technology.

All key components – hydraulics, electronic hardware and software – are developed and manufactured in-house exclusively by HEINZMANN.

ODYSSEUS Benefits

 Permanently high fuel system pressures at any engine speed/

load point for optimised fuel vaporisation inside the combustion chamber

 Flexibly programmable multiple injection strategy

 Engine speed/load dependent injection mapping

 Injectors can be adapted to fit various cylinder heads

 Wide range of control units:

for engines up to 20 cylinders

 Safe and compact rail, piping and cable harness

 Complete common rail startup, support for combustion

optimisation, system training by HEINZMANN Technical Service

 Support of design process and reliability approach by using SolidWorks

^®

* Simulation

Professional & Flow Simulation

 Hydraulic system optimisation using AMESim

^®

* simulation software

 Applicable for Micro Pilot common rail fuel injection for gas engines

Injector test bench

* All Trademarks are the property of their respective owners.

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ODYSSEUS SYSTEM COMPONENTS

 Control Unit

 High-pressure Pump

 Rail

 Injectors

 Sensors

Sensors

Control unit

High-pressure

pump Fine-mesh

fuel fi lter

Prefi lter

TANK

High-pressure accumulator (rail)

Flow limiter

Fuel injector

Low pressure

fuel line Pressure

control valve Phasing sensor

Injector control

E.g. oil pressure

& temperature sensor

Coolant temperature sensor Speed sensor (2x)

Boost pressure

& temperature sensor

Exhaust gas temperature sensor Fuel

temperature sensor

HEINZMANN components

The HEINZMANN ODYSSEUS Common Rail System consists of

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HDP-K2

Í Unique crank mechanism design Í 2 pressure elements

Í System pressures up to 2000 bar Í Versions with 6, 8, 10 & 12 mm stroke Í Plunger diameter: Ø 8 mm

Í Pump speed up to 2400 rpm Í Delivery rates up to 2.3 l/min Í Oil lubricated

Í Flow control valve with HEINZMANN solenoid (actuated via DARDANOS ECU)

Í With or without pre-feed pump Í Rated for long endurance Í Good serviceability Í Flange mounted

HDP-K3

Í System pressures up to 2000 bar Í Versions with 12 & 16 mm stroke Í Plunger diameter: Ø 10, Ø 12, Ø 14 mm Í Pump speed up to 3600 rpm (12 mm stroke) Í Delivery rates up to 15 l/min (1 x pump;

redundant concept: 2 x pump up to 30 l/min) Í Oil lubricated

Í With or without pre-feed pump

Í Robust design, rated for long endurance Í Good serviceability

Í Easy adaptable (flange or socket version)

ODYSSEUS HIgH-PRESSURE PUMPS

HDP-K2, HDP-K3 and HDP-K4

HEINZMANN common rail high-pressure pumps feature the new and unique crank mechanism design.

The reciprocal movement of pressure elements is driven by a solid con-rod connection with pump crank shaft. This state-of-the-art principle in the field of diesel fuel pumps is featured in all HEINZMANN pumps in various versions and sizes for different applications, delivery rates and fuel qualities (distillate and heavy fuel oils).

The HEINZMANN high-pressure pump family design excels with high delivery rates and high pump efficiencies because of relatively compact but robust design especially for the needs of industrial applications even under demanding environmental conditions (vibration, dust, off-road application, etc.).

In operation, HEINZMANN high-pressure pumps are practically wear-free when inspected after operation for the normal service lifespan of conventional diesel fuel common rail pumps. This is because commonly available cam-roller pumps suffer wear due to line contact of the cam and roller whereas the connecting rod bearings of HEINZMANN’s HDP-K pumps are designed to run hydro-dynamically on a film of lubricant. Also, the con-rods in HEINZMANN’s HDP-K series pumps mechanically pull the pistons back on the non-pressure stroke compared to conventional pumps which rely on springs to return the pistons on the non-pressure stroke.

For the same reason there is no risk of accelerated wear due to roller-jumping at maximum operating speeds as in cam-roller pumps.

The connecting rod bearings decouple side forces (typical stress effects on pump plungers and elements within cam-roller solutions) which are generated by rotation of pump shaft. A cross-head piston with special plunger connection design transmits virtually no side-force effects on the HDP-K plungers. This results in very low wear effects on pump elements and coated plungers as well as correspondingly long TBO periods.

The above mentioned plunger connection mechanism has a fail-safe function. The mechanism disconnects non-destructively plunger from cross-head piston and crank shaft.

The HEINZMANN HDP-K high-pressure pump family consists of three basic sizes: HDP-K2, HDP-K3 and HDP-K4.

HDP-K2

HDP-K3

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ODYSSEUS INJECTORS

HEINZMANN has developed a completely new injector generation with sophisticated features:

The new ICR-DS injector generation features a leak free design. Only a small amount of control volume returns to fuel backflow. HEINZMANN has achieved a considerable reduction of fuel backflow by 75 % (compared to conventional leakage afflicted common rail injector designs) and of fuel return temperatures.

The main design attribute for leak free operation is the

“diving needle”.

The pressurised fuel enters ICR-DS injectors through the high-pressure fuel port directly into the injector integrated accumulation volume with incorporated diving needle. The integrated accumulation volume (rail volume) has a beneficial effect on damping peak pressures within the hydraulic system and especially within highly stressed inner parts of

injectors. HEINZMANN has achieved reduction of peak pressures inside ICR-DS injectors by 25 % by means of integration of accumulation volume. Additionally, good fuel flow within the accumulator has been taken into account during design process. This is of highest importance especially for HFO operation.

With the diving needle design, HEINZMANN fuel injection nozzles have only one single central bore- hole which acts as needle guide and fuel feed at the same time. The simplified and leak free nozzle results in robust and rugged design without material debilitating second bore-hole and greatly reduced risk of nozzle cracks. Injectors and nozzles for HFO operation feature less susceptibility to cat-fines and lacquering effects.

The electronically controlled injectors are actuated by HEINZMANN solenoid technology with strong magnetic force, fast response time and compact size.

High-pressure pump HDP-K3 HFO

Í System pressures up to 1.800 bar Í Designed for HFO operation

Í Delivery rates up to 15 l/min (1 x pump;

redundant concept: 2 x pump up to 30 l/min) Í Engine oil lubricated

Í Special two-way HFO/lube-oil sealing concept Í Mix oil drain

Í Sealing oil

Í Special design for high-temperature operation (HFO)

Í Robust design, rated for long endurance Í Good serviceability

HDP-K3 HFO

High-pressure pump HDP-K4 HFO

Í System pressures up to 1.800 bar Í Designed for HFO operation

Í Delivery rates up to 35 l/min (1 x pump;

redundant concept: 2 x pump up to 70 l/min) Í Engine oil lubricated

Í Special two-way HFO/lube-oil sealing concept Í Mix oil drain

Í Sealing oil

Í Special design for high-temperature operation (HFO) Í Robust design, rated for long endurance

Í Good serviceability

HDP-K4 HFO

1600 35000

0 2500 5000 7500 10000 12500 15000 17500 20000 22500 25000 27500 30000 32500 35000

0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200

Pump Delivery Rate (ml/min)

Pump Speed (rpm)

HDP-K Pump Family: Delivery Rate vs. Pump Speed @ 1.800 bar HDP-K4_1826

HDP-K3_1216

HDP-K3_1016 HDP-K2 HDP-K3_1416

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ODYSSEUS ICR-DS-100

For engines with cylinder power up to 100 kW Í Medium-sized common rail injector for injection

pressures up to 2.000 bar and injection quantities in a range of 10…500 mm³/shot.

Í Designed for distillate diesel fuels.

Í Suitable/adaptable for Micro Pilot common rail fuel injection systems.

ODYSSEUS ICR-DS-300

For engines with cylinder power up to 300 kW Í Large-sized common rail injector for injection

pressures up to 1.800 bar and injection quantities in a range of 50…4.000 mm³/shot.

Í Designed for distillate diesel fuels and heavy fuel oil (HFO).

Í Cooled nozzle.

ODYSSEUS ICR-DS-500

For engines with cylinder power up to 500 kW Í Large-sized common rail injector for injection

Í Designed for distillate diesel fuels and heavy fuel oil (HFO).

Í Cooled nozzle.

ODYSSEUS ICR-DS-200

For engines with cylinder power up to 200 kW Í Medium-sized common rail injector for injection

ODYSSEUS ICR-DS-50

For engines with cylinder power up to 50 kW Í Small-sized common rail injector for injection

pressures up to 1.800 bar and injection quantities in a range of 2…170 mm³/shot.

Í Suitable/adaptable for Micro Pilot common rail fuel injection systems.

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













 













 









 

 

























 







 















 

 





 

 

 

















    











 







  







































 



 







 

















 

































 























  



 











 

  





 







 









_





















































 

































 

 

  















 























 

























































 







  







































 











  













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ODYSSEUS CONTROL UNITS

DARDANOS

The DARDANOS series is designed as universal speed controllers for engines with electronically-controlled injection systems. In addition to their primary purpose of controlling speed, these controllers provide

additional features that offer other benefits for your diesel engines.

The MVC versions are designed for electronically controlled diesel injection systems. The HEINZMANN devices are based on an outstanding experience and technological background in EFI control systems. They offer optimised fuel efficiency, increase of engine power, lower environmentally harmful emissions and reduced smoke especially during startup and acceleration.

TECHNICAL INFORMATION

MVC 01-20

for up to 20 cylinders

MVC 03-8

MVC 04-6

* dependent on system components

Air humidity up to 98 % at 55 °C Contamination resistant against substances

typically present in the engine environment Vibration max. 2 mm with 10 up

to 20 Hz,

max. 0.24 m/s with 21 up to 63 Hz

max. 9 g with 64 up to 2000 Hz

Shock 30 g,

11 ms – half-sine wave Protection grade IP65

Isolation resistance > 1 MOhm with 48 VDC MVC 05-4

Supply voltage 24 VDC

Min. voltage 18 VDC*

Max. voltage 32 VDC

Max. ripple voltage max. 10 % with 100 Hz Output voltage for 24 VDC / 48 VDC /

solenoids 90 VDC

(MVC 01-20)

Output voltage for 48 VDC / 60 VDC solenoids

(MVC 03-8, MVC 04-6, MVC 05-4)

Current consumption avg. 1 A / injector Storage temperature -55 °C up to +105 °C Ambient temperature -40 °C up to +80 °C

-40 °C up to +120 °C with fuel coolant

EFI Control System –

MVC 01-20 / MVC 03-8 / MVC 04-6 /

MVC 05-4

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HIgH-PRECISION MANUFACTURINg

Assembly of common rail compo- nents and systems in cleanroom

areas

All high-precision components (plungers, valves, nozzles etc.), manufactured and cleaned in our production areas, are assembled in special cleanrooms. The assembling rooms are separated by two- gate air locks from the production area.

Two gate air lock

High-precision machines and equipment:

Í High-precision external grinding machines (Studer)

Í High-precision internal grinding machines (Studer)

Í High-precision coordinate grinding machine (SIP-Hauser)

Í Precision CNC-lathes (Mazak, Spinner, Schaublin)

Í Precision CNC-milling machines (Heller, Hermle)

Í Highest quality lapping machines (Stähli)

Í Honing machines (gehring, Pemamo)

Í EDM drilling machines (Posalux)

Í Hydroerosive rounding and calibrating machines (Sonplas) Í ECM machines (Kennametal) Í Ultrasonic cleaning equipment

(different manufacturers)

High-precision: what is 1 µm ?

HEINZMANN is able to perform manufacturing in high- precision areas below 1 µm ie, less than 0.001 mm.

To demonstrate the accuracy which is needed, the illustration below shows the comparison of the human hair diameter and one µm.

Comparison of the diameter of a human hair with the diameter of one µm.

Human hair diameter: 0.05 mm

And this is 1 µm:

0.001 mm

Cleanroom assembling area

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Studer S 145-CNC

Internal grinding machines

Production of high-precision bores (valve seats and needle-guides) of hardened high-resistant pure materials for injection nozzles, pump cylinders control and safety valves.

Highest precision and best repeatability in the submicron tolerance range.

Í Roundness: 0.4 micrometer

Í Concentricity of needle-seat geometry:

1-3 micrometer

Í Surface quality: Ra/Rz 0.1/1 micrometer

Posalux FP series

Precision-drilling machines for

small bores (EDM, electro discharge machine)

Application:

Í High-precision bores in hardened steel and special super alloys Í Cylindric and

conical spray hole geometry, diameter in a range of 80 – 400 micrometer Í CNC

controlled:

complete geometry and process parameter data library Cleanroom production area

Studer S 31 CNC

External grinding machines

Í Production of high-precision rotary parts: pump- plungers, valve- and nozzle needles of hardened high-resistant pure materials, highest precison and repeatability

Í Roundness: 0.4 micrometer Í Cylindricity: 0.5 micrometer

Í Surface quality: Ra/Rz 0.1/1 micrometer

STÄHLI FLM 500

Drilling of spray holes in a HEINZMANN common rail fuel injection nozzle Typical HEINZMANN high-pressure injector-control module

with high-precision bore and lapped sealing surfaces for 2000 bar operation.

High-precision valve-plate for HFO-pump

Stähli FlM series

Sealing surfaces for high-pressure injectors, nozzles, pumps and valves require special sealing geometries and best surface quality,

controlled by HEINZMANN with interferometer methods, measured and documented by MAHR roughness analysis instruments.

Typical HEINZMANN high-pressure injec- tor-control module

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High-pressure pumps on endurance test bench

Injectors on endurance test bench

HIgH-PRECISION MEASUREMENT AND QUAlITY ASSURANCE

HEINZMANN products stand for reliability and precision. Product quality is of highest priority at HEINZMANN, so every product is checked before, during and after manufacturing using sophisticated techniques. Maximum precision is achieved by using state-of-the-art measuring and test equipment:

Í Dimensional control:

3D coordinate measurement Í Contour measuring:

Roundness, parallelism, cylindricity, straightness

Í Surface measuring:

Roughness Í Shape testing:

Measurement of shape and position tolerances

Quality control equipment

HEINZMANN executes analyses for quality control of prototypes and serial parts in their own modern equipped laboratories.

All test results are documented and stored in secured internal and external data bases.

Our own material laboratory is able to prepare probes for metallurgical, structural and hardness analyses within minutes.

With high end optical instruments, internal structures such as rounding of spray holes, galleries, bore crossings etc. and surfaces are inspected and documented.

The durability of HEINZMANN ODYSSEUS high- pressure parts and complete systems are tested day and night on fully automated endurance test benches.

Injection parameters (pressure, flow, injection timing, speed, temperature) are controlled and documented by a highly sophisticated monitoring system.

Quality assurance with state-of-the-art equipment

3D coordinate measurement

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ODYSSEUS APPlICATIONS

0,14 0,12 0,1 0,08 0,06 0,04 0,02

0

0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5

Particulate

(g/kWh)

NO

_x(g/kWh)

EGR / late injection timing

Improvement of combustion State-of-the-art

USA ‘07

EURO 5, 2009 EURO 4, 2004

EURO 3, 1999

FUEL CONSUMPTION

USA 2004

 Agriculture vehicles

Fig.: Technologies for the fulﬁ lment of future international emission legislation

HEINZMANN ENgINE CAlIBRATION SERVICES

The growing demands of our customers are the driving force at HEINZMANN. Our development program focuses on the optimisation of the combustion process in diesel engines. By developing state-of-the- art products we satisfy the needs and expectations of our customers, whatever their priorities. HEINZMANN has the ideal solution, whatever is required, be it power, fuel efficiency, acoustic performance, or compliance with legal requirements for engine modifications, such as future international emission restrictions. HEINZMANN uses up-to-date testing facilities for all categories of engines and applications.

HEINZMANN is well known for electronic fuel injection controllers. This technology offers several improvements over the characteristics of current diesel engine systems. Future enhancements can be achieved by reducing engine exhaust emissions (e.g.

NOx, HC, CO and particulates), combustion noise and fuel consumption. HEINZMANN offers expertise and state-of-the-art testing facilities for engines up to 600 kW, enabling us to support customers in the optimisation of their engines equipped with HEINZMANN electronic fuel injection systems.

 Truck

 Bus

 Railway

 Railcar

 generator

 Marine

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ETM_ODY_001_10_12_e_1_2010

www.heinzmann .com

Head Offi ce:

Heinzmann GmbH & Co. KG

Am Haselbach 1

D-79677 Schönau/Germany Phone: +49 7673 8208 - 0 Fax: +49 7673 8208 - 188 Email: info@heinzmann.de

Quality & Precision since 1897

SAFETY SYSTEMS

CONFIGURATION TOOLS

COMMON RAIL

SENSORS AND

SOLENOIDS DUAL FUEL CONTROLS

GAS ENGINE MANAGEMENT

TURBINE MANAGEMENT

ENGINE EMISSION MANAGEMENT ELECTRIC AND HYDRAULIC ACTUATORS GENERATOR MANAGEMENT HYBRID

TECHNOLOGY DIGITAL AND ANALOGUE

CONTROL SYSTEMS ELECTRONIC FUEL

INJECTION