ECM EGR 5230 Instruction Manual
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ECM EGR 5230 Instruction Manual

Egr/dual lambda/o2 analyzer
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EGR 5230
EGR/Dual Lambda/O
Analyzer
2
Instruction Manual
11/08/2017

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Summary of Contents for ECM EGR 5230

  • Page 1 EGR 5230 EGR/Dual Lambda/O Analyzer Instruction Manual 11/08/2017...
  • Page 2  COPYRIGHT 2017 by ECM: ENGINE CONTROL AND MONITORING. All Rights Reserved. No part of this manual may be photocopied or reproduced in any form without prior written consent from ECM: ENGINE CONTROL AND MONITORING. Information and specifications subject to change without notice.

  • Page 3: Table Of Contents

    A. 5200 Series Instruments Parts List B. Module EIB Mode and Stand-alone Mode C. Error Codes and Troubleshooting D. Calculating the %O in Air E. LOCKing and unLOCKing Display Head F. Using the Configuration Software G. Setting up ETAS INCA for ECM Analyzers...
  • Page 4 H. Setting up ATI Vision for ECM Analyzers I. Using the Lambda (O ) Sensor Simulator J. Remote Control of the Analyzer over CAN Safety Warnings Warranty and Disclaimers...

  • Page 5: Introduction

    Introduction The EGR 5230 The EGR 5230 is a very compact exhaust gas recirculation (EGR) ratio measurement device with the following features:  Measures both volume and mass-based EGR ratios  Can be used in diesel and spark ignition engines ...

  • Page 6: Theory Of Operation

    (internal EGR). During throttled engine operation, even with the EGR valve closed, a non-zero %EGR can be measured due to this intake flow. The EGR 5230 cannot differentiate between the two EGR flows. It just measures the %EGR at the location of the intake O sensor.
  • Page 7 Figure 1: EGR 5230 Installed on Engine...

  • Page 8: Egr 5230 Kit Contents

    EGR 5230 Kit Contents The following items are in the EGR 5230 kit: Item No. Description Part Number EGR 5230 Display Head 01-03 LambdaCANp Module, (2 required) 02-08 (P/N 02-01 LambdaCAN Modules supplied with earlier analyzers) Lambda (O ) Sensor, Bosch LSU 4.2, Type P, (2 req.) 05-05 Pressure Sensor with ¼”...
  • Page 9 Pressure Cable, 1 m, (2 required) 10-35 These cables have 8-terminal connectors. (P/N 10-04 Pressure Cables required for earlier analyzers that use LambdaCAN Modules. These cables have 4-terminal connectors.) DC Power Cable, Banana Plugs 11-16 Female Eurofast to DB9F 11-05 Key-on Cable, 2 m 11-08 18 mm x 1.5 mm Mild Steel (MS) Boss and...

  • Page 10: Operating The Egr 5230

    (N, C) is contained on a label attached to the pressure sensor’s harness. These numbers must be manually entered into the display head for the upper (intake) and lower (exhaust) channels (see CAL, P, N, C). Pressure sensors must be sent back to ECM for recalibration.

  • Page 11: In-Use Recalibration

    O2 sensor cooling or excessive drifting/aging is a problem with the P/N 12-04 boss, alternative sensor mounting techniques can be used. For example, the peek spacers shown below. Contact ECM (support@ecm-co.com, or 408-734-3433 (California, USA) for more information.

  • Page 12: How To Use

    100 m. The EGR 5230 can be turned on and off by the PWR button on the front of the display head or by a voltage signal (2.7 - 32 V) applied to the KEY connector on the back of the display head.
  • Page 13 EIB with Power Entry at Module End Connect Module EIB Connector Display Head Pressure Sensor Sensor Pressure Line Power Entry Assembly Figure 2: EGR 5230 with Power Entry at Module End...
  • Page 14 EIB with Power Entry at Display Head End Power Entry Module Connect EIB Connector Pressure Sensor Display Head Sensor Pressure Line Assembly Figure 3: EGR 5230 with Power Entry at Display Head End...
  • Page 15 Cable P/N 02-08 LambdaCANp Module (for Intake or Exhaust) P/N 01-03 Optional: P/N 04-01 P/N 11-16 (P/N 02-01 EGR 5230 AC/DC Power Supply, DC Power Cable, LambdaCAN modules Display Head Universal, 24 V Banana Plugs (shown), supplied with earlier or P/N 11-15 (Spades)
  • Page 16 CAN Bus P/N 13-01, Manuals and Flexi-Eurofast Connector Configuration Tool Cable P/N 01-03 Connector EGR 5230 Display Head Optional: P/N 12-01 19” Rackmount Panel Figure 5a: Part Numbers of Components near Display Head Figure 5b: Front and Back of Display Head...
  • Page 17 P/N 02-08 LambdaCANp Module (P/N 02-01 LambdaCAN modules supplied with earlier analyzers) P/N 10-34, 0.2 m, Module Y Cable (P/N 10-21 Y Cable required for earlier analyzers that use LambdaCAN modules) P/N 05-05 Bosch LSU4.2, Type P, Sensor P/N 10-35, 1 m, or P/N 10-36, 2 m Pressure Sensor Cable (P/N 10-04, 1m, or P/N 10-05, 2m P/N 10-02, 1 m...

  • Page 18: Mounting The O 2 Sensors And Pressure Sensors

    Mounting the O Sensors and Pressure Sensors Sensors   Thread is 18 mm x 1.5 mm.  Mount intake O sensor using tall aluminum 18 mm boss (P/N 12-04, see Figure 7) to the intake manifold where the %EGR is to be measured. ...
  • Page 19 P/N 12-07, ¼” NPT Aluminum Boss and Brass Plug, (USA), or P/N 12-14, ¼” ISO tapered Aluminum P/N 12-04, 18 mm x 1.5 mm Tall Aluminum Boss, Boss and Brass Plug, (Metric). Copper (Cu) Gasket, and Aluminum Plug. For Intake Pressure Sensor. For Intake O Sensor.

  • Page 20: Front Panel And The "Sys" Key

    Front Panel and the “SYS” Key The EGR 5230 display head can be thought of as two single-channel display heads in one package. The intake lambda module (attached to intake O and pressure sensors) is assigned (via the MOd Setup Option) to the upper display, upper four leds, and analog outputs 1, 2, 3 (i.e.
  • Page 21 AEGV to APEX only on upper display. CONF appears only on lower display and is for global display head setup. All entries must be followed by the ENT key. Table 1: Menu Tree for the EGR 5230 [Default values given within square parentheses]...

  • Page 22: Mod (Module) Setup Option

    MOd (Module) Setup Option In MOd setup, the serial number of the lambda module assigned to the upper (MOdi) or lower channel (MOdx) is entered. The serial number is written on a label on the module (see Figure B1). The module attached to the intake O and pressure sensors must be assigned to the upper channel and will send information to the upper display and the analog outputs 1, 2, and 3.
  • Page 23 PPSI P (psi) Pressure sensor measured pressure (absolute) in psi PERF Pressure error bit flags Pressure sensor bit flags (LambdaCANp only) PERC CANopen error code CANopen pressure sensor error code (LambdaCANp only) Table 2: Parameter List for the EGR 5230...

  • Page 24: Disp (Display) Setup Option (P1 To P4)

    CAL (Calibrate) Setup Option  sensors supplied with the EGR 5230 are factory calibrated. This calibration is stored in a memory chip inside the sensor’s connector. With use, O sensors can age requiring recalibration to maintain measurement accuracy.
  • Page 25 9. When “CAL” is displayed, press SYS to return to RUN model. See AGEF (below). 10. The user calibration is written into the memory chip in the O sensor’s connector and , , AFR, Φ, and FAR. If the O will be used to calculate EGR , EGR , %O...
  • Page 26 AGEF (O sensor age factor) After the O sensor has been user-calibrated, data from this calibration is compared to data taken from the sensor when it was new. From this, a parameter (AGEF) is calculated that indicates the relative sensitivity of the sensor compared to when it was new. If AGEF is 1.00, the sensor’s sensitivity has not changed.
  • Page 27 Pressure sensors cannot be user-calibrated but can be recalibrated by ECM.  Raw data is sampled from the O and pressure sensors every 5 ms. This data is averaged by the lambda module every 5 ms before being sent to the display head every 5 ms. For the , , AFR, Φ, FAR, the averaging filter is ILAM (one ILAM for intake...

  • Page 28: Conf (Configure) Setup Option (Leds, 1V4V, Can, Lock, Fact)

    CONF (Configure) Setup Option CONF setup appears at the end of the setup list for the lower channel. To enter CONF, press the SYS key until “MOd” appears on the upper display, press the  key until “CONF” appears on the bottom display, and then press the ENT key. CONF relates to display head (as opposed to lambda module or sensor) setup.
  • Page 29 The CAN data is broadcast at 500 kHz in the following format: CANid byte 0 byte 1 byte 2 byte 3 byte 4 byte 5 byte 6 byte 7 CID1 What is being sent to analog output 1 What is being sent to analog output 2 CID2 What is being sent to analog output 3 What is being sent to analog output 4...

  • Page 30: Specifications And Limits

    Specifications and Limits Measurements and Accuracies Parameter Range Response Time Accuracy %EGR , %EGR 0 to 100 < 1 sec. ±0.5% (absolute) ±0.6% (at =1) Lambda () 0.4 to 25 < 150 ms ±0.9% (avg, elsewhere) ±0.6% (at =1) 6 to 364 <...
  • Page 31 Fuel Composition: H:C ratio range: 1.00 - 10.00, or Hydrogen (H O:C ratio range: 0.00 - 10.00 N:C ratio range: 0.00 - 1.00 gasoline: 1.70 < H:C < 2.10, O:C=0.0, N:C=0.0, (1.75 or 1.85 are commonly used) methanol: H:C=4.0, O:C=1.0, N:C=0.0 ethanol: H:C=3.0, O:C=0.5, N:C=0.0 propane: H:C=2.67, O:C=0.0, N:C=0.0 methane: H:C=4.0, O:C=0.0, N:C=0.0...

  • Page 32: Output Specifications

     Pressure Sensor Tubing Note: Stainless steel end of tubing towards engine. Teflon end towards pressure sensor. Mating Thread with Engine: ¼” NPT (USA) or ¼” ISO tapered (Metric) Tubing Assembled Length: 28” (USA) or 711 mm (Metric) Tubing Diameter: ¼” (USA) or 6mm (Metric) Nut, Front Ferrule, Back Ferrule at Pressure Sensor end of Tubing: Swagelok SS-402-1, SS-403-1, SS-404-1 (USA) or Swagelok SS-6M3-1, SS-6M4-1, SS-6M2-1 (Metric)

  • Page 33: General Specifications

    Current Draw: 0.5 A (display), 1.2 A steady-state (per module and sensors), On start-up, O sensor and module may draw as much as 4 A for 30 s. Case Ground: The EGR 5230 display head case is connected to power ground via a 2.15 kΩ resistor.  Key-on Signal “ON”...

  • Page 34: Appendices

    01-01 NOx 5210 (just head, no module, no cable, no sensor) 01-02 Lambda 5220 (just head, no module, no cable, no sensor) 01-03 EGR 5230 (just head, no module, no cable, no sensor) 01-04 dashCAN (includes cable and T) 01-05 dashCAN+ (6 analog outputs, includes cable and T)
  • Page 35 05-04 NTK 4 mA 05-05 Bosch LSU4.2, Type P 05-06 Delphi OSL 05-07 NTK 4mA Cofired (ZFAS-U2) 05-08 Bosch LSU4.9, Type P 05-09 Bosch ADV 05-10 NTK, 6mA, Type P 05-11 Bosch LSU4.2, Type PI (Intake) 05-12 CO, CO2 06 NOx and NH3 Sensors 06-01 NOx Original (use with NOxCAN) 06-02 NOx Type "G"...
  • Page 36 09-04 Flexi-Eurofast Cable, 0.3m 09-05 Eurofast "T" 09-06 Eurofast Termination Resistor 09-07 Eurofast Male Connector 09-08 8 Channel Eurofast Hub Block 09-09 Termination Resistor for Hub Block 09-10 CSM-Type Lemo Terminating Resistor 10 Sensor Cables 10-01 Module Y Cable (not LambdaCANp, COCO2CAN, baroCAN, Superseded by -21) 10-02 1m Sensor Cable, (12 term.) 10-02/25' Sensor Cable, (12 term., teflon) 10-03 2m Sensor Cable, (12 term.)
  • Page 37 10-42A 1.5m LambdaCANp Cable, Lemos at Midpoint, Controller Side 10-42B 1.5m LambdaCANp Cable, Lemos at Midpoint, Sensor Side 11 Cables 11-01 DC Power Cable, DB9F, Spades 11-02 DC Power Cable, DB9F, Banana Plugs 11-03 DB9M to CSM Lemo F Adapter (CSM Upstream) 11-04 DB9M to ETAS Lemo Adapter 11-05 Female Eurofast to DB9F 11-06 Male Eurofast to CSM Lemo F Adapter (CSM Downstream)
  • Page 38 12-07 1/4" NPT Al Boss and Brass Plug, (USA) 12-08 Pressure Line Assembly, 1/4" dia, 28" (USA) 12-09 Inconel Shield 12-10 18mm Cu Gasket 12-11 Pressure Line Assembly, 6mm dia, 711mm (Metric) 12-12 1/4" ISO tapered MS Boss and Brass Plug, (Metric) 12-13 1/4"...
  • Page 39 13 Software, CAN Adapters, and Manuals 13-01 5200 Series Manuals and Config Software (CD) 13-02 Kvaser Leaf Light CAN Adapter 13-Product Name (Manual) 14 Tools 14-01 18mm x 1.5mm Tap 14-02 18mm x 1.5mm Die 14-03 ¼” NPT Tap 14-04 ¼” ISO Tapered Tap 14-05 Antiseize 14-06 Metal Brush to clean sensor threads 14-07 Lambda Sensor Calibration System...

  • Page 40: Module Eib Mode And Stand-Alone Mode

    LambdaCAN* modules can be used in conjunction with an analyzer (EIB mode) or on its own (Stand-alone mode). When used as part of an analyzer (ex. Lambda 5220, EGR 5230), the module is setup in EIB mode. When delivered to be used alone, the module is setup in Stand-alone mode.
  • Page 41 2. Start the Configuration Tool (software). Click on the “Module” tab. Select the CAN adapter being used. Then start the communication. 3. Click on the “Set to EIB Mode”. Wait for “Done” Message. Stop communication and exit program.
  • Page 42 4. Take the nut off the end of the module. Use an 18mm socket without the wrench. 5. Release the two tangs at each side of the module. 6. Slide the PCB out. Remove the jumper from JP4. You can hang it on one pin of JP4 when “off”.
  • Page 43 7. Make sure both O-rings are on the threaded connector. 8. Slide the PCB into the enclosure until the two tangs “click”. 9. Put the nut on and tighten ONLY ½ turn from where it is seated. If this nut is tightened too much, the connector will crack and the enclosure will not be sealed.

  • Page 44: Error Codes And Troubleshooting

    Appendix C: Error Codes and Troubleshooting If one of the EGR 5230’s displays flashes “ERR” followed by “####” (the Error Code), an error has been detected in that channel’s module (or attached sensors). The below table lists the errors. The errors are also flashed on the module’s LED.

  • Page 45: Calculating The %O

    Appendix D: Calculating the %O in Air The Configuration Tool Software has a routine to calculate the %O in air. If the software is not available, the below may be used. The oxygen concentration in dry air (zero humidity) is 20.945 and decreases with increasing humidity.
  • Page 46 1. Press SYS until “LOCK” is displayed. Then press ENT. 2. “50” will be displayed. Press  until “60” is displayed. Then press ENT. Display is now unLOCKed. If an unauthorized person learns that 60 is the key number, contact ECM.
  • Page 47 Appendix F: Using the Configuration Tool Software ECM’s Configuration Tool runs on a PC and is for use with ECM’s analyzers and modules. The Configuration Tool is supplied on a CD with each analyzer and module and is available for download on www.ecm-co.com.
  • Page 48 To do this: 1. For EGR 5230 v13.9 & below: a. In the Configuration Tool software, press “Manual Add Device”. A “Waiting for Analyzer…” window will appear. Leave it open. b. On an analyzer, press SYS, arrow down to CONF, press ENT, arrow down to CAN, press ENT, and with “IdS”...
  • Page 49 6. The analog parameters are called A#_sn where “#” is the analog output number and “sn” is the serial number of the display head (ex. A1_45405300). The serial number is the first thing that is displayed on startup on the display head. The display parameters are called TopDisp_sn, and BtmDisp_sn.

  • Page 50: Setting Up Etas Inca For Ecm Analyzers

    2. Connect the Ethernet port directly to the Ethernet port on your PC. This port does not use an internet/intranet connection like a router. 3. Connect either the CAN1 or CAN2 port to a CAN network (i.e. ECM analyzer(s) and/or module(s)).
  • Page 51 5. Configure the hardware. Click on the icon for the workspace you created in step 3. Open the Hardware Configuration icon under the section text “6. Hardware”. A hardware configuration window will open.
  • Page 52 6. Select the hardware. In the hardware configuration window, right click the “HWK Workspace” listed under the section text “1. Hardware Devices”, and select Insert. Select the ETAS device you wish to use. In this example, we are using an ETAS ES591.1.
  • Page 53 8. Initialize hardware. The hardware is currently stopped, as indicated by the red stop sign icon next to the selected hardware. You must initialize it before you can use it to collect data. Click on the Initialize Hardware button on the upper tool bar and wait for the hardware to complete its initialization.
  • Page 54 10. Select and Configure Variables. Select the variables that you wish to monitor in the Experiment Environment. These variables names are based on the data found in the dbc file. Click Configure. 11. Another window will pop up to configure each selected variable. You can configure, for each variable, whether to record or simply display the data, how the data will be displayed (graphs, charts, gauges, numeric, etc.).
  • Page 55 13. Start CAN monitoring. Right now there is no data displayed. That is because the CAN monitoring is stopped. To begin CAN monitoring, click on the Start Visualization icon (blue triangle) on the left hand tool bar. To stop CAN monitoring, click the Stop Measuring icon (black square) on the left hand tool bar.
  • Page 56 LambdaCAN to the PC to CAN adapter. Supply 11-28V DC (5A min. supply) to the LambdaCAN. For the case of an ECM analyzer (ex. Lambda 5220), connect to CAN port on display head. Do not directly connector to modules.
  • Page 57 Creating a .dbc File The ECM Configuration Tool is used to create a .dbc database file for describing the CAN messages broadcast from an analyzer or module. All ECM products with a CAN interface use the CANopen protocol at 500kHz by default. To generate a .dbc file from an analyzer, refer to Appendix F.
  • Page 58 ATI VISION CANMonitor provides a method of reading general purpose information from any available CAN channel. The .dbc file generated by the ECM Configuration Tool is used to describe the format of the information available to VISION. To setup a CANMonitor in ATI VISION: 1.
  • Page 59 3. Add a physical hardware device by clicking Device  Add Device, and select Kvaser CAN Channel. 4. Select a CANMonitor device by again clicking Device  Add Device, and select CANMonitor.
  • Page 60 5. Add the .dbc file generated from the ECM Configuration Tool to CANMonitor by clicking Device  Add CAN Database and browsing to the previously created .dbc file. 6. Enable the hardware by clicking Project  Online. The status of all of the devices should now show a Status of Online, and a value should appear in the Data Rate column of the Project window.
  • Page 61 7. To view data, create a new Screen File and add a Control. Click File  New  Screen File 8. Select Object  Add Control  Gauge...
  • Page 62 9. In the Select Data Items window open the CANMonitor file tree to view all of the available signals. Here the O2% from Node 0x10 has been selected. Click OK to add the Data Item to the Control. 10. Data should be visible on the gauge.
  • Page 63 A properly operating LambdaCAN* module monitors lambda sensor condition and can calibrate the lambda sensor. An external pressure source is required to check out the pressure sensor. Lambda Sensor Simulators can be returned to ECM on a schedul e (1 year recommended) for recalibration.
  • Page 64 Appendix J. Remote Control of the Analyzer over CAN From version 14.0 and on, the analyzer can be controlled remotely via its CAN port. This section describes what functions can be performed via CAN and how to do it. You can connect multiple analyzers on the same CAN bus.
  • Page 65 single targeted analyzer into configuration mode. These commands duplicate the functions available when navigating through the “SYS” menu via the front panel buttons. Many of these functions are explained in the “SYS” section of this manual. For more info on each task, please see the corresponding section of the manual.
  • Page 66 Set Constants 0x2A Bit 4-7 (0xF0): 1=top 2=bottom Bit 0-3 (0x0F): For Punits, 0=psia, Indexes 0-5 are applicable to both top & 0=ILAM 1=mmHg, 2=kpaa, bottom modules independently. Indexes 6- 12 are only applicable to “top” module. 2=PLAM 3=bar, 4=kgcm. 3=Punits All others, use Indexes 4-5 are only applicable when using...
  • Page 67 module not ready, or no module selected processing error busy processing last request Analyzer Info Response The following block of 38 CAN messages are sent in response to a request for device info (command 0x0F). The messages are in a format similar to the Data Response reply outlined above, with the exception of the Sub-cmd used to identify the info in the block, i.e.
  • Page 68 Never work on a running engine. When installing the EGR 5230’s cabling and sensor(s) on a stopped engine, it is best to think- out your moves before you make them. Route and cable-tie all cables away from hot, moving, sharp, or high voltage (spark) objects.
  • Page 69 Warranty and Disclaimers WARRANTY The products described in this manual, with the exception of the O and pressure sensors, are warranted to be free from defects in material and workmanship for a period of 365 days from the date of shipment to the buyer. Within the 365 day warranty period, we shall at our option repair such items or reimburse the customer the original price of such items which are returned to us with shipping charges prepaid and which are determined by us to be defective.
  • Page 71 AFM1600 Lambda and O Analyzer DIS1000 Display Head EGR 4830 Analyzer Lambda 5220 Lambda Analyzer NOx 5210 NOx Analyzer EGR 5230 EGR Analyzer LambdaCAN, LambdaCANc, LambdaCANd, LambdaCANp Lambda Modules NOxCAN, NOxCANg, NOxCANt NOx Modules NOx1000 NOx Module baroCAN Module dashCAN, dashCANc, dashCAN+, dashCAN2...
  • Page 74 Los Altos, CA 94023-0040  USA  (408) 734-3433  Fax: (408) 734-3432  www.ecm-co.com...

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