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EGR 5230
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. 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, CAN, USB, and RS232 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: Expose the O2 and pressure sensors to 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.

Video Tutorial for Producing .dbc Files
Ranges:%EGR 0 to 100%
λ 0.4 to 25
AFR 6 to 364
φ 0.04 to 2.5
O2 0 to 25%
Pressure 0 to 517 kPa
Accuracies:%EGR ± 0.5% (absolute)
λ, AFR, φ ± 0.6% (at stoichiometric), ± 0.9% (average, elsewhere)
%O2 ± 0.1% (absolute)
Pressure ± 1.7 kPa (± 0.25 psia)
Response Times:%EGR less than 1 second (programmable)
λ, AFR, φ, %O2, pressure less than 150 ms
Fuel Types:Programmable H:C, O:C, and N:C ratios, and H2
Analog Outputs:6 channels, 0 to 5V linearized and programmable for %EGR, λ, AFR, φ, O2, pressure, etc
CAN:Programmable communication protocol
USB, RS232:Data transfer and control
Power:8 to 28 VDC, AC/DC supply is optional (P/N 04-01)
Sensor:18mm x 1.5mm thread (O2), 1/4" NPT (pressure)
Size and Cable:105mm x 64mm x 165mm (W x H x D), 6m cable (std), up to 100m (optional)
Operating Temp.:Electronics -40 to +85°C
Sensor 850°C (maximum continuous)
Options:Rackmount Kit (holds up to 4 analyzers), O2 sensor simulator, AC/DC Power Supply
Jump to Optional Kits and Parts
Related Downloads:
EGR 5230 Brochure (11-12-2014, 253KB)
Aluminum Block Brochure (27KB)
Bifurcated Intake Probe Brochure (419KB)
Exhaust Probe Brochure (104KB)
Rackmount Installation Guide (197KB)
Vboost Power Supply Brochure (165KB)
ETAS INCA Setup Guide (1052KB)
ATI VISION Setup Guide (504KB)
ECM CAN Configuration Tool (v4.48.10, 31499KB)
Firmware Update Procedure for Display Heads (158KB)
Ordering Information, Complete Kit P/N: EGR 5230 Analyzer Kit
The complete kit includes the following parts:
1.5230 Display Head01-031
2a.LambdaCANp Module, or02-082
2b.LambdaCAN Module
(For older EGR 5230s)
3.Bosch LSU4.2, Type P, O2 Sensor05-052
4a.Pressure, Type KP, 0-75 psia, 1/4" NPT (USA), or07-102
4b.Pressure, Type KP, 0-517 kPa, 6mm (Metric), or07-112
4c.Pressure, Type KP, 0-75 psia, 1/4" NPT (USA)
(For older EGR 5230s), or
4d.Pressure, Type KP, 0-517 kPa, 6mm (Metric)
(For older EGR 5230s)
5a.Pressure Line Assembly, 1/4" NPT Tubing/Hose/Fittings, 28" Length (USA), or12-082
5b.Pressure Line Assembly, 6mm Tubing/Hose/Fittings, 711mm Length (Metric)12-112
6.Eurofast 12mm Cable, 4m09-011
7.Eurofast 12mm Cable, 2m09-022
8.Flexi-Eurofast Cable, 0.3m09-044
9.Eurofast "T" Connector09-055
10.Eurofast Termination Resistor09-063
11a.Module Y Cable (For LambdaCANp only), or10-342
11b.Module Y Cable (For older EGR 5230s)10-212
12.Lambda/NOx/NH3 Cable, 1m10-022
13a.Pressure Cable (8-terminal), 1m, or10-352
13b.Pressure Cable (4-terminal), 1m
(For older EGR 5230s)
14.DC Power Cable, Banana Plugs11-161
15.Female Eurofast to DB9F11-051
16.Key-on Cable, 2m11-081
17.18mm x 1.5mm Mild Steel Boss and Stainless Steel Plug12-021
18.18mm x 1.5mm Tall Aluminum Boss, Copper Gasket, and Aluminum Plug12-041
19a.1/4" NPT Mild Steel Boss and Brass Plug (USA), or12-051
19b.1/4" ISO Mild Steel Boss and Brass Plug (Metric)12-121
20a.1/4" NPT Aluminum Boss and Brass Plug (USA), or12-071
20b.1/4" ISO Aluminum Boss and Brass Plug (Metric)12-141
21.5200 Series Manuals & Configuration Software CD
This PC-based software allows configuration of CAN communication, calibration of sensors, and data logging. Requires Kvaser, Vector, or Peak USB-to-CAN adapter. (Available from ECM, see P/N 13-02 below)

Optional Kits and Parts:

1.AC/DC Power Supply, Universal, 24VDC 4.2A
(Highly Recommended for Dynamometer Installations)
2.Vboost Power Supply (Boosts supply voltage to avoid dropout situations)04-021
3.DC Power Cable, Spades11-151
4.Eurofast 12mm Cable, 10m
(Highly Recommended for Dynamometer Installations)
5.Lambda/NOx/NH3 Cable, 2m10-031
6.Lambda/NOx/NH3 Cable, 3m10-371
7.Pressure Cable (4-terminal), 2m
(For older EGR 5230s)
8.Pressure Cable (4-terminal), 3m
(For older EGR 5230s)
9.Pressure Cable (8-terminal), 2m10-361
10.Pressure Cable (8-terminal), 3m10-381
11.CAN-to-USB Adapter13-021
12.19" Rackmount Panel (holds up to 4 display heads or 4 dashCANs)12-011
13.Aluminum Remote Sensor Mounting Block (18mm x 1.5mm, 5 x 1/4" NPT)12-181
14.Individual Cylinder Exhaust Probe (18mm x 1.5mm) (USA)12-191
15.Individual Cylinder Exhaust Probe (18mm x 1.5mm) (Metric)12-201