EGR 5230 Analyzer

(Measures Exhaust Gas Recirculation, O2, Pressure, Lambda, AFR)

MPN: EGR5230-XX Category:

Exhaust gas recirculation (EGR) is a powerful control used to suppress NOx emissions in engines.  As important as EGR is to the operation of engines, in the past there has been no simple and compact way to measure it.  Now there is with ECM’s EGR 5230 Analyzer.

The EGR 5230 determines the %EGR by measuring the O2, oxidizable concentrations, and pressures directly in the intake and exhaust of the engine under test.  Because there are no pumps drawing samples from intake and exhaust of the engine, the instrument is non-intrusive and has response times of less than one second.  There is also a dramatic reduction in maintenance in comparison to other systems.

The EGR 5230 can display both volumetric and mass-based %EGR as well as Lambda, AFR (air-fuel ratio), intake %O2, exhaust %O2, intake pressure, and exhaust pressure and is programmable for all fuel types (H:C, O:C, N:C ratios, and H2).  The analyzer can also function as a dual-channel, pressure compensated Lambda (AFR) meter if the intake sensors are relocated to the exhaust.  With six analog outputs and CAN communication, the EGR 5230 can be integrated with any data acquisition system.

Set-up of the EGR 5230 is easy: Mount the ceramic O2 sensors in the intake and exhaust of the engine using 18mm x 1.5mm bosses and route pressure taps from the intake and exhaust to the EGR 5230’s pressure sensors.

Calibration of the EGR 5230 is simple: Hold the O2 and pressure sensors in air and press a button on the instrument’s front panel.  Calibration data for the O2 sensors is stored in a memory chip in the sensor’s connector.

The EGR 5230 is fast: This means the analyzer can be used to develop dynamic EGR algorithms.  More can be done and tried in less time.  The EGR 5230 is small: now you can measure in a vehicle and on the road.

EGR and Lambda (AFR) are the two most important parameters influencing the emissions, fuel economy, and drivability of engines.  Measure these parameters quickly, easily, in the laboratory and in vehicles with the EGR 5230.

Response Time %EGR: less than 1 s (programmable)
λ, AFR, φ, %O2, Pressure: less than 150 ms
Fuel Type Programmable H:C, O:C, and N:C ratios, and H2
Power 11 to 28 VDC, AC/DC (optional)
Sensor Mounting Lambda: 18mm x 1.5mm thread
Pressure: 1/4" NPT/ISO
Dimensions 105mm x 64mm x 165mm (W x H x D)
6m cable (std), up to 100m (optional)
Operating Temperature Electronics: -40 to +85°C
O2 Sensor: 850°C (maximum continuous)
Ranges & Accuracies
EGR 0 to 100% (± 0.5% absolute)
λ 0.4 to 25 (± 0.6% at stoichiometric, ± 0.9% average elsewhere)
AFR 6 to 364 (± 0.6% at stoichiometric, ± 0.9% average elsewhere)
F/A 0.003 to 0.167 (± 0.6% at stoichiometric, ± 0.9% average elsewhere)
φ 0.04 to 2.5 (± 0.6% at stoichiometric, ± 0.9% average elsewhere)
O2 0 to 25% (± 0.1% absolute)
Pressure SAE: 0 to 75 psia (± 0.1 psia)
Metric: 0 to 517 kPa (± 0.7 kPa)
CAN Programmable communication protocol
Analog 6 channels, 0 to 5V linearized and programmable for %EGR, λ, AFR, ϕ, O2, etc.

Included Analyzer Components

The base kit includes the following:

Pressure-compensation (SAE version) is included for each channel and adds the following:

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Pressure-compensation (Metric version) is included for each channel and adds the following:

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Calibration Tools

To ensure the accurate operation of the EGR Analyzer, we divide the analyzer into two parts: the sensor and everything else.

For the sensor, we have a 4-channel Lambda Sensor Calibration System.  The calibration system uses ambient air for a calibration gas and are designed for traceable calibration in a large facility.

For “everything else”, we have the Lambda Sensor Simulator.  The simulator simulates the currents and voltages from perfect Lambda and pressure sensors in a perfectly known gaseous environment.  Thus the analyzer, module, cabling, and the user’s data acquisition system should respond accordingly.  If the expected output of the analyzer is not seen, there is a problem with the analyzer, module, cabling, or the data acquisition system.

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EGR 5230 Manual (Ver. 2017-11-08, 3 MB)
Rackmount Installation Guide (193 KB)
Vboost Power Supply Brochure (162 KB)
Firmware Update Procedure for Display Heads (155 KB)
ECM Configuration Tool (Ver. 4.48.20, 30 MB)
TechNote Engine Stoichiometry (66 KB)