WAGER 6500 User manual

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FAX: [phone]
Email: [email protected]
Homepage: http://www.wagerusa.com
USA: 1-800-562-7024
CANADA: 1-800-655-5585
Telephone: [phone]
Robert H. Wager Co., Inc.
570 Montroyal Road, Rural Hall, NC 27045
Rack Mount In-Line Operation Manual

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TABLE OF CONTENT
Warranty Information ...............................................................................................................
General........................................................................................................................................
System Description....................................................................................................................
System Components .................................................................................................................
System Components Continued .........................................................................................
Technical Specifications.........................................................................................................
Initial Installation ......................................................................................................................
Optical Beam Alignment Procedure ...................................................................................
Diagnostic Values.....................................................................................................................
Adjustment .................................................................................................................................
Follow Mode Test......................................................................................................................
APPENDIX A -- MAINTENANCE................................................................................................
APPENDIX B -- TROUBLE SHOOTING...................................................................................
APPENDIX C --SPECIFICATION...............................................................................................
APPENDIX D -- DEFINITIONS ..................................................................................................
APPENDIX F CONFIGURING CONTROL UNIT.......................................................................
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Seller expressly warrants to Buyer (a) that the equipment will comply with the
description set forth herein; (b) that the components and parts fabricated by Seller will
be free from detrimental defects in workmanship and materials.
If it appears within one year from date of shipment by Seller that the equipment does
not meet these express warranties and Buyer gives Seller prompt and reasonable
notice, Seller shall, at its option, either repair or replace at its expense, F.O.B. Seller’s
works, but not dismantle or reinstall, the defective parts provided, upon request such
parts are shipped freight prepaid to Seller’s works.
These warranties shall not apply if equipment is subjected to other than normal and
proper storage, handling, installation, operation and maintenance or to unauthorized
repairs or alterations. Equipment, components and accessories made by other
manufacturers are warranted only to the extent of the original manufacturer’s warranties
to Seller.
The foregoing warranty obligation of the seller shall constitute the sole and exclusive
remedy of the buyer and the sole liability of the seller, except as set forth herein and
except as to the title it is expressly agreed (a) that there is no warranty of
merchantability of any other warranty, express, implied or statutory, nor any affirmation
of fact or promises by Seller with respect to the equipment or parts or otherwise which
extend beyond the specifications mutually agreed upon in writing by Seller and Buyer,
and (b) that the Buyer acknowledges that it is purchasing the equipment solely on the
basis of the commitments of Seller expressly set forth herein, in no event shall Seller be
liable for special, indirect, or consequential damages including, without limitation,
anticipate profits.

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The WAGER Model 6500 Rack Mount Smoke Opacity meter is in full compliance with the
requirements of SAE J1667 test criteria. It is specifically for dynomometer test cells and stationary
testing of stack emissions. The LCD displays opacity in percentage value, and the analog output
at the rear of the unit outputs 0-1 VDC that corresponds to a digital readout. This analog output is
used to go to a data acquisition system or a chart recorder.
The meter’s simple design and rack mount makes it easy to access and obtain accurate
measurements. It provides an accurate means ( +/- 1% ) of detecting and measuring the opacity
of smoke emitted by a diesel engine.
The use of the Model 6500 IL promotes combustion efficiency for fuel economy and ensures
compliance with diesel emission standards set by air quality codes.
The program document for SAE J1667 is Surface Vehicle Recommended Practice. It can be
obtained from:
SAE International
400 Commonwealth Drive
Warrendale, Pa. 15096-0001 Telephone [phone]
Or electronically at:http://www.arb.ca.gov/msprog/hdvlp/saej1667.pdf

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Control Unit
Power Supply
Connection Cable 50Ft.
Receiver with Air and Water Chamber
Transmitter with Air and Water Chamber
Neutral Density Filter .2ND
Fuse 2A 250VAC 5X20MM
Fuse Holder
Instruction Manual
194-0003-RACK
194-0004R
192-0015
194-0043
194-0044
194-0034
4143551
627-0123
6500R Manual
Description Part Number

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STACK PIECE/Sensor Head Assembly
Stack Piece / Sensor Head Assembly
Stack Pieces are available in a variety of sizes. Standard stack size for
an in-line is 8”. Custom stack pieces are available in any diameter upon
request. The standard material is schedule 40 carbon steel. Stainless
steel is also available upon request. Connections may be flanged or
welded.
Control Unit
The control unit is operated by a membrane keypad, which consists of
eight tactile feedback push buttons. The display is an alphanumeric
LCD containing 16 characters by two rows. In low light situations, the
display can be backlit. The display shows the prompts the operator
follows throughout the test sequence(s). Up to 100 test can be stored in
the system’s memory. The banana jacks (red and black) allow a 0 –1
VDC output or data acquisition.
AIR CHAMBER FLANGE
The Air Chamber Flange is threaded and mated to the stack piece. It
uses positive air pressure to help maintain the cleanliness of the lens
sets.

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Water Chamber Flange
The water chamber flange has two (2) retaining hooks that clip onto the optics.
It contains a port for incoming flow of water, and one for outgoing. The flow of
cold water reduces the temperature in the optics, and keeps them cool during
lengthly testing procedures.
Connecting Cable
The Connecting Cable is made to withstand high temperatures for long
durations. Standard length is 50 feet. Additional lengths are available upon
request.
Power SUPPLY
The meter is shipped with an AC Adapter/Charger which operates under
110V or 220V with our export version.
The meter does contain a timeout feature that will turn the unit off
automatically if none of the front panel buttons are pressed for 20
minutes.
Neutral Density Filter
To assure continuous accuracy a .2 neutral density filter ( Melles Griot ) is
supplied with the system. We recommend a check before and after each
day’s testing.

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The Wager Model 6500 Smoke Meter meets SAE J1667 specification for full flow
meters, Appendix C, using the required algorithm.
Accuracy
The unit’s accuracy is 1.0% nominal one digit. The control unit is initially
calibrated under clear stack conditions with checks at 0% and 100% opacity.
The accuracy of the unit is verified by use of the .2 Melles Griot neutral density
filter supplied with the system.
Ambient Conditions
The unit operates in 32° to 120° F (0° to 50° C). Control unit is for indoor use only and should not
be exposed to water.
Reliability
Zero stability at less than 1% drift per use.
The pulsed green LED has infinite life expectancy.
Check filter provided for easy calibration
All solid state electronics.
Manufactured by an ISO 9002 company.
Applications
The Model 6500 Smoke Meter can be used on any diesel engine, with primary
application in testing trucks, busses, and cars.
Contact WAGER for special applications, such as stand-by power, mining
operations, railroad use, boating/maritime, industrial, etc.
Functional Description
When the unit is activated, the transmitter emits a light beam at a known
intensity. As the light passes through the smoke plume, some or all the light is
diverted.
The sensor head consists of two components, a light source (transmitter) and a
light detector (receiver).
The light detector measures the amount of light received, and compares this
with the amount of light being emitted. The difference between the two values is
opacity.

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Initial Installation
The inline optics require alignment once the stack piece is permanently mounted. In most
application, the optics have a threaded air-chamber flange that screws onto the pipe of the
stack. Positive pressure clean air hoses can be attached to the air flange to provide air flow
keeping the internal glass free of soot and particles.
Bolted to the threaded air-chamber flange is the water-chamber flange. Two threaded
ports are available on the water chamber to attach in-coming and out-going water hoses to
keep the temperature of the assembly in a safe range. If you are using the flow of water,
ensure that there are both in-coming and out-going pipes. In some high-temperature
applications, a earth tone temperature-insulator ceramic block maybe be installed between
the water and air chambers.
Two adjustable clips are used to attach the optic housing to the water chamber flange.
Adjust the clips as to hold the housing firmly but not as to over-pressure the clips. The optic
set consists of one transmitter (TX) and one receiver (RC). The transmitter emits a visible
green light and can be identified by inspecting the connector. The connector on the TX has
7 pins. The receiver receives the green light and uses this light to determine opacity. The RC
can be identified by the connector that has 5 pins.
Since the system uses light to determine opacity, the alignment of the beam is critical to
system operation. The beam of light must be aimed as to illuminate the receiver directly and
fully.
Receiver Transmitter

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Optical Beam Alignment Procedure
Once the hoses, pipes and optics are mounted, removing the 3 screws and protective cover
will expose the electronics and lens tube. Remove the protective cover on both the TX and
RC. Inspecting this area, you will see a green circuit board mounted with 3 screws and also
will see 3 larger screws that mount the lens tube in the optic housing. The lens tube is
spring-loaded with the 3 larger screws and acts as a tripod. Adjusting these larger screws
will affect the direction of the beam and the angle of the receiver.
Connect the cable to TX, RC, and the control unit. The control unit has a diagnostic mode
that will display the digital values of the amount of light within the optics.
.
Beam Adjustment Screws
Potentiometer Gain
Adjustment Screw

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Diagnostic Mode
Start with the control unit off. Hold the ZERO and START TEST buttons down while powering
on. The control unit should display CONFIGURATION MODE. If not, turn the unit off and try
again. Once you see CONFIGURATION MODE, release all buttons. Then press SELECT three
times. Next press COMPUTE AVERAGE once. Finally, depress ZERO and then SELECT in a
quick manner. This pressing of the SELECT freezes the automatic gain control and is
required to stabilize the digital values.
Upon completion of this button series, the LCD will show three values. If you do not have 3
values, turn the meter off and start again.
The top left value is the LED DRIVE value and should not be changing and should be steady
stable. The value is not important just as long as it is between 1500 and 3500 and is stable.
The bottom left number is the TRANSMITTER value and the top right number is the RECEIVER
value.
The goal of the optic alignment is to have the TX and RC values to be equal and around
2800.
.
LED Drive Value
Transmitter Value

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ADJUSTMENT
Start on the transmitter. Inspect the value displayed and adjust the brass flat-head screw of
the potentiometer on the circuit board. The potentiometer is a 20 turn device and has a
self-protect mechanism. If you hear it click, you are at the limit and further turns will not
affect the value. Clockwise (CW) increases the value and counter-clockwise (CCW)
decreases the value. Adjust the transmitter potentiometer for a value of 2800. Once the TX
value is 2800, no further adjustment of this potentiometer is required.
Staying at the TX, inspect the value of the RC on the display. Remember anything over 4000
is max limit. So if ever the receiver value displays 4000, turn the RC potentiometer CCW to
2800.
The three spring-loaded screws affect the beam angle. Remaining at the TX, adjust the
screws CW one at a time to increase the RC displayed value to a maximum value. For
example, adjusting screw A one turn will take the value from 1700 up to 2200 but any further
turns on this screw will start to lower the RC value from 2200 back to 2000. So in this case,
adjust screw A back to 2200. Then proceed to screw B. Adjusting screw B takes the value
from 2200 up to 2350 but then starts to decrease again. Adjust screw B back to 2350.
Repeat this process on the transmitter for all screws to obtain receiver maximum value.
Now proceed to the receiver. Repeat this procedure on the 3 spring-loaded screws on the
RC. If at anytime the RC value goes above 4000, turn the RC potentiometer CCW to 2800.
Lastly, after all the 6 spring-loaded springs have been adjusted for a maximum value on the
receiver display, adjust the receiver potentiometer for a value of 2800.
Turn the meter off and go into the diagnostic mode and verify the values of the TX and RC
are approximately equal and then re-install the protective covers.
.

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Follow Mode Test
The “Follow” mode provides a means of providing a continuous “real life”
opacity reading and performing tests under load, either on the road or on a
dynamometer.
To set the unit to the follow mode, turn the unit on. After seeing the date and time,
the top line of the display will show the mode the unit is operating in. If the unit
displays " MODE = TEST SERIES" press the zero button to toggle the mode. Now the
unit should display "MODE = FOLLOW".
Once you see CALIBRATION COMPLETED, it is too late to alter the mode and the
unit should be powered off and then back on to gain access to the point where
the mode can be changed.
Press the ON/OFF button on the control unit. The unit will perform a
self-calibration.
Press the SELECT button until the desired stack size is displayed (factory default
is 5”). Press the SAVE button.
The HP shown corresponds to the default horsepower. If your engine has
different specifications, press SELECT until the correct value is displayed. Press
SAVE.
Press the START TEST button.
Follow your state’s test requirements as to RPM and load factors.
When you have reached the governed load, press SAVE.

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Follow mode tests cannot be printed on the impact printer. However, the data
can be captured and displayed graphically through the software supplied with
your CPU interface.
The data can be printed in “real time” by keeping the optional Linseis Recorder
attached while the test is performed.
Analog Output
The WAGER Model 6500 Smoke Meter outputs a 0 – 1 V signal through the
banana jacks (located next to the AC power input plug).
The output voltage reflects the opacity output where 0 V is 0 % opacity and 1 V
= 100% opacity. The red jack is positive and the black jack is negitive.

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Cleaning Lenses
To assure regular easy access to the lenses, we have provided two snap
closures. The lenses can be wipes with a soft cloth.
We strongly recommend that a regular procedure of calibration and cleaning the
lenses is established. During light use, a daily cleaning may be enough. During
heavy testing, we recommend a frequent cleaning throughout the day.
To remove soot, dip soft cloth in denatured rubbing alcohol (make sure to let it
dry) and rub gently over lenses.
In laboratory settings and heavy commercial use, please note that we have
provided connectors for an external air purge.
Connecting Cables
Connecting cables are subject to wear, based on incorrect handling, abuse, and
contact with a hot stack. Check, repair, and replace cables when their condition
affects the operation of the smoke meter.
Verification with Neutral Density Filter
The Melles Griot Neutral Density Filter allows you to verify that that the system
operates within the ± 1% tolerance. Once the unit is operational, insert the filter holder into
the filter slot. The meter should display a reading that cooresponds to the filter value.

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Each filter is attached to a chart, which shows that particular filter’s calibration
line. The column on the right will show the corresponding percent transmission
value.
Conversion Table of Optical Density vs. Percent Transmission
For this example, we assume that this filter’s line is slightly below the .20 line.
(greyed area in the chart above). The calibration line is at 0.19. This gives you a
density of 64.57.
To obtain the opacity reading, subtract 64.57 from 100 (total blockage of light)
for an opacity reading of 35.43.
When you use this filter to check your unit, a reading between 34.43 and 36.43 is
considered “within specification.”
Please make a note of your filter’s original value when it is factory fresh.
The deterioration of the filter with exposure to light is gradual and may not be
detected unless compared to the original values.
DENSITY % TRANSMISSION
OR REFLECTION
0.24
0.23
0.22
0.21
0.20
0.19
0.18
0.17
57.54
58.88
60.26
61.66
63.10
64.57
66.07
67.61
Mean Line .2

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The WAGER Model 6500 Smoke Meter has been designed to be nearly trouble
free for many years of use.
However, some components are subject to unintentional abuse, which is not
covered in our warranty.
Error Messages
CABLE FAILURE DISCONNECTED?
The light source is fully powered, but no light is detected receiver. This could be
caused by several factors:
=The sensor head assembly cable is not connected to the control unit
=The light source in the sensor head assembly has failed.
=The connecting cable is malfunctioning.
Action:
Check to make sure that the cable is firmly attached to the unit.
If another unit’s sensor head assembly and cable is available, try to see if this corrects
the error.
If the message disappears, then you need to send in the sensor head assembly and/or
cable for repair.

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Further troubleshooting can be found on our website at wagerusa.com. Click the red
cross to quick link to the troubleshooing page.
SENSOR FAILURE REQUIRES REPAIR
This indicates that the light source is functioning, but the receiver is not receiving the
output.
A dirty lens on either the transmitter and/or the receiver side.
Malfunction in the sensor head assembly or cable.
Action:
Clean the lenses as described in “Maintenance” section. If this does not correct the
problem, call WAGER Technical Services for assistance.
MEMORY FULL DELETE TESTS FIRST
The unit saved 100 tests and has reached full storage capacity.
Either you have saved 100 tests, or the unit has experienced some electrical shock that
has reset the number of saved tests. The unit immediately goes into the Print and
Delete Test Series mode after displaying this message.
Action:
Use the ZERO to delete test series.

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Electrical Specifications
Mechanical Specifications
Performance Specifications
Light Source
Light Sensor
Display
Meter Accuracy
Peak Hold
Recorder Output
Charging Transformer
(Model AD-1880)
Led - Green Gallium Phosphide 570 NM
Si Photo Diode with IR Filter
(Backlit) Liquid Crystal Display (LCD)
1.0% Nominal, 10th digit
No Drift
0-1 Volt or 0-1 MA
120 VAC 22 Watts in /18 VDC @800 MA out
-
+-
+
Size
16 3/4" W x 6 1/2" D x 4 1/2" H
Rack Dimensions
Range:
Warm up Time:
Response Time/Display*
Response Time (Chart Recorder
Output)
Linearity
Zero Stability (Drift)
Temperature Stability, Sensor Heads
0.0% - 100.0% opacity
Negligible
0.45 seconds for 0-90% opacity
0.45 seconds for 0-90% opacity
1% from 0-100% opacity
Less than 1% in 60 minutes
1% from 32 Degrees - 120 Degrees F
-
+
-
+

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Follow Mode
A Configuration mode selectable item that allows the unit to continuously read
opacity and maintain a “peak hold” reading. The alternate mode is Test Series
Mode. A Configuration mode selectable item that causes the Model 6500 to run a fixed
series of Snap Acceleration Tests as dictated by the Society of Automotive
Engineers (SAE) in specification J1667. The alternate mode is Follow Mode
Opacity
The percentage of light transmitted from a source that is prevented from
reaching a light detector.
Preliminary Snap Acceleration Test
A series of Snaps (usually at least 3) performed before testing begins to clear
the exhaust system of residual particles.
Snap Acceleration Test
The engine is allowed to run at maximum RPM’s for 4 to 5 seconds and brought
back to idle. Three “snaps” are taken for this test. Each individual test is stored
and a mathematical formula applied to provide an “average.” See Page 14 for
step-by-step instructions.
SAE J1667
A document created to outline specifications to manufacturers of opacity meters,
as well as test criteria for performance of opacity (smoke) readings.