WAGER 7500 User manual

SMOKE OPACITY METER
570 MONTROAL RD, RURAL HALL, NC 27045
[phone] • 1-800-562-7024 (US) • WWW.WAGERUSA.COM

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WARRANTY INFORMATION.................................................................................................................
WARRANTY STATEMENT.....................................................................................................................
GENERAL..............................................................................................................................................
MINIMUM SYSTEM REQUIREMENTS FOR CUSTOMER’S OWN COMPUTER.................................
SYSTEM DESCRIPTION.......................................................................................................................
TECHNICAL SPECIFICATIONS............................................................................................................
SET-UP FOR TESTING.........................................................................................................................
QUICK START INSTRUCTIONS...........................................................................................................
PERFORMING A SNAP ACCELERATION TEST..................................................................................
INTERFACE SOFTWARE......................................................................................................................
TECHNICAL SUPPORT.........................................................................................................................
APPENDIX A- MAINTENANCE.............................................................................................................
APPENDIX B- GENERAL FIELD PRECAUTIONS...............................................................................
APPENDIX C- SPECIFICATIONS.........................................................................................................
APPENDIX D- DEFINITIONS.................................................................................................................
APPENDIX E- NEW JERSEY SPECIFIC TESTING REQUIREMENTS................................................
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TABLE OF CONTENT

Robert H. Wager Co., Inc.’s full, legal warranty statement is printed on the following page. Here is a
quick overview:
The customer is required to return the malfunctioning unit freight prepaid to:
Robert H. Wager Co., Inc.
Attention: Technical Services
570 Montroyal Road
Rural Hall, NC 27045
Please request a Return Authorization if at all possible. We need at least your return shipping address, a
contact with telephone and fax number (in case we have questions), and an explanation of the type of
error message or problem you have encountered.
Robert H. Wager Co., Inc. will make the appropriate repairs as rapidly as possible (usually within three
working days) and return the unit freight prepaid unless otherwise instructed.
If Robert H. Wager Co., Inc. finds—at its sole discretion—that the malfunction was due to customer
abuse, misuse, attempts to repair, or other conditions caused solely by the customer, the warranty is
void. The unit will be repaired in the normal manner and the customer is invoiced.
In order to establish the date of your purchase and match the serial number of the unit to our records,
we require the attached form “Warranty Registration” to be filled out and returned to us.
We reserve the right to alter, amend, or adjust our warranty policy without further notice.
WWAARRRRAANNTTYY
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WWAARRRRAANNTTYY
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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 statu-
tory, 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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GENERAL
The Model 7500 Smoke Meter is in full compliance with the requirements of the SAE J1667 test
criteria—the current U.S. standard.
The standard requirements are:
40% opacity vehicles 1991and newer,
55% opacity vehicles between 1990 and 1974
70% opacity on vehicles 1973 and older.
We have preset the pass/fail criteria to those points.
In addition, specific requirements for New York and New Jersey’s test have been accommodated with
the appropriate screen prompts, error messages, and information in the printout.
The meter’s simple design and portability makes it easy to 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 7500 Smoke Meter promotes combustion efficiency for fuel economy and ensures
compliance with diesel emission standards set by environmental 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, if you have access to the Internet, a copy can be downloaded from the web site maintained by
California Environmental Protection Agency, Air Resources Board.
http://www.arb.ca.gov/msprog/hdvip/saej1667.pdf

MINIMUM SYSTEM REQUIREMENTS
FOR CUSTOMER’S OWN COMPUTER
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Windows XP, Vista, Windows 7 Operating System
CD ROM and 3 ½ " Floppy Drive
64 MB RAM, Pentium or Celeron 800 MHz or Higher
VGA/SVGA graphics adapter with 800 x 600 min screen resolution
One USB port (for connection to DCU) - or - One 9 pin serial port Parallel Port, and a parallel port for
connection to the printer
*NT SP-6, or higher
Note:
If you are using your own system, there are some files you need to load that will match the
filter value and record them on your system. To load the information from the floppy disk
provided, see “New Filter Section” section.
To perform the actual filter calibration see “Set-Up for Testing” section.
Please call 1-800-562-7024, ask for “Technical Services” and we will assist you in loading the
proper file. Instruction Manual Model 7500 Smoke Meter (New Jersey Version) 14

SYSTEM DESCRIPTION
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Data Collection Unit
The DCU collects data from all attached sensors and commu-
nicates with the computer. The banana jacks (red and black)
allow a 0 –1 VDC output for a chart recorder.
Sensor Head Assembly (Partial Flow)
The partial flow sensor head is attached to the vehicle exhaust
in accordance with the criteria in the SAE J1667 document.
(The document describes the different stack configurations and
the placement of the sensor head).
The Partial Flow Sensor Head is shipped with a straight,
curved, and clamping style nozzle. The nozzles are attached
with simple snap buckles.
The Bayonet (straight) Nozzle
The bayonet (straight) nozzle hooks over the straight stack..
The Curved Nozzle
The curved nozzle has a stop that allows correct positioning.
The Clamping Style Nozzle
A clamping style nozzle is for quick and easy placement.

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Cable
The connecting cable is 25 feet long. An optional 25' extension
cable is available.
Power
The meter is shipped with an AC Adapter/Charger, which
operates in 110V. The 12 V sealed, lead-acid cell battery will
allow up to 40 hours of continuous operation with a full charge.
Calibration Filter
A .2 Neutral Density Filter (Melles Griot) is supplied with the
system. It is a small round glass in a special holder for the
partial flow head.
A special "Calibration" sequence is available on the main menu
screen. It will prompt you to insert the filter as shown below.
The date of the last calibration will be added to your test print-
out.
Extension Pole
A telescoping extension pole is designed specifically
for each system. It allows the operator to attach the
sensor head to the stack from the ground.

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Shop Cart
Used in a shop setting to provide ease of daily service.
Printer
An HP Deskjet. USB Port, full page portable, battery-
operated color ink-jet printer. Or any printer will
oper-ate under a Windows environment.
Carrying Case or Shop Cart
Several options are available to provide easy portability or
convenient shop use. Please call us or email
[email protected] to discuss your needs.

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Description Part Number
Model 7500 Smoke (Opacity) Meter System Components
Data Collection Unit (DCU) 196-0008-1
Power Supply Transformer 110V 196-0006
Hewlett-Packard Desk Jet 450CBI Printer PRINTER
12V, Sealed, Lead-Acid Battery 196-0030
Fuse 4143551
RPM Phototach Kit (w/base) 196-0012
RPM Extension Cable 195-0018
Reflective Tape, 1 inch wide (per yard) 579-0003
Oil Temperature Probe 195-0023
Oil Temperature Extension Cable 10’ 195-0019
25’ Connecting Cable 192-0003A
25' Extension Cable 191-0011
*Partial Flow Sensor Head (lens set below) 194-0028
Transmitter Assembly 147-0164
Receiver Assembly 147-0165
Curved Nozzle 194-0018-C
Straight Nozzle 194-0018-S
Clamp Nozzle 194-0018-SC
Extension Pole, Partial Flow Head 147-C0092-PF
Neutral Density Filter .2 in holder (for PF head) 194-0029-2
Serial Interface Cable 196-0001
Serial/USB Converter Cable 196-0017
Instruction Manual 7500 Manual
*P/N for sensor head assembly is listed without lens set.
Please call us for any item not listed here.
SYSTEM DESCRIPTION

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TECHNICAL SPECIFICATIONS
Design Criteria
The Wager Model 7500 Smoke Meter meets SAE J1667 specification, Appendix C, using the required
algorithm.
Accuracy
The unit’s accuracy is ± 1.0% nominal ± one digit. The system 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).
Please note that under N.J.A.C 7:27B-24, additional ambient conditions apply. This is addressed under
“NJ Ambient Conditions”.
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.
Applications The Model 7500 Smoke Meter can be used on any diesel engine, with primary applica-
tion 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
The sensor head consists of two components, a light source (transmitter) and a light detector (receiver).
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 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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SET-UP FOR TESTING
Important:
New Jersey Regulation N.J.A.C. 7:27B-4 requires a number of test criteria that are above and beyond
the SAE J1667 document. If you are to perform testing in New Jersey, Please be sure you are familiar
with all requirements set forth in the document.
Installation of Sensor Head
Full Flow Head:
Position the sensor head over the top of the exhaust stack with the extension handle.
Partial Flow Head:
Use either the curved, straight, clamping style nozzle depending on the shape of your stack. The strong
magnets on the extension pole will assist in placing the head correctly into the stack.
Attachment of Connecting Cables
The connecting cable is attached to the DCU and the sensor head assembly by means of “MultiMate”
connectors. The ends of the cable have connectors that will fit into matching grooved receptacles.
Align the pins on a connector with the holes on its mating receptacle. Insert the connector into its mating
receptacle. Lock the connector in place by screwing the locking ring clockwise until a firm connection is
made.
Repeat these steps for all required sensors.
Oil Temperature Probe
The oil temperature probe inserts into the oil pan as you would insert the normal dipstick. Attach the
plug end as described above.
Note:
The oil temperature probe requires approximately 90 seconds to acclimate from normal room tempera-
ture to the engine oil temperature.
RPM (Photo-Tach) Sensor
Pull off approximately 1 inch of reflective tape provided with the system. If the damper is very new and
glossy, a small area may have to be smudged to make it matte. It is recommended that the optical
sensor be placed at a slight angle (15 degrees) from perpendicular, so that only pulses
from the reflective marker will be received by the sensor. The sensor should be at least 1
inch from the reflective target to avoid false triggering. Attach the plug end as described
above.
Reflective Tape can be ordered per yard. Call 1 800 562-7024 or write
[email protected].

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Filter Calibration
New Jersey State Requirements require a valid filter calibration to be performed every seven days.
The Model 7500 software has been programmed to flash the red “filter calibration” button when this is
due. (NJ Software revisions only)
You will not be able to proceed with the test until this calibration has been performed. You can still
access the System Configuration and the Logfile Maintenance files while this lock-out is in effect.
The Melles Griot Neutral Density Filter allows you to verify that that the system operates within the
acceptable range. Each filter’s calibration range is set when the system is shipped.
Neutral Density Filter
To assure continuous accuracy of the opacity test performed, a .2 Melles Griot Neutral Density Filter is
provided with the system. The system will lock out further use after seven days, until the calibration
test has been performed. (NJ Software revisions only)
After calibration sequence has been performed, the date of the test will be printed with each succes-
sive test print out.
Note: Neutral Density Filters are manufactured to very exacting standards. They have a finite life
expectancy, which can be extended, if they are kept in a dry dark place between uses.
If you are using your own computer, or if you have purchased a
new filter, a floppy disk has been supplied which will add the
calibration values to your system. See next page for instruc-
tions.

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New Filter
A filter will come with a floppy disk containing data required for the 7500 to calibrate properly. You will
only need to perform this task once for the duration of the life of the filter. To load the data on to the
CPU, start at the Wager DCU main menu and select "System Configuration". Then, on the bottom left
select "New Filter". Insert floppy disk into the drive and click "OK" The system will prompt to replace the
file. Click replace. Remove floppy disk and store in proper place.
Filter Calibration Test
From Main Menu, press “Filter Calibration” button. Connect all sensor to the DCU and the laptop. Make
certain the system is turned on, and the DCU has been reset. Press “Calibrate” button with clear light
path. System will prompt to insert the calibration filter and then press “Start.” Allow the system to record
the filter value for approximately 10 seconds. It will stop automatically and check the filter value. The
system will show either one of the following messages: Test Passed, updating calibration date. The
system will automatically update the 7 day calibration date. It will shut down the software for changes to
take effect. If the filter is outside the specified range, the system will display "Test Failed". To re-test,
remove the filter and press the calibration button again. If the failure message continues, contact the
Wager Company.
SAEJ1667 Snap Acceleration Test
The Model 7500 Smoke Meter has been designed in accordance with the specifications of SAE J1667.
The meter will prompt the operator through the required test sequence, compute the average, spread,
and zero drift. New Jersey (Rev. 1) 21

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Connect all sensor head, RPM
Sensor and Oil Temperature
Probe to DCU.
Connect DCU to the laptop using
the supplied interface cable. (You
might want to connect the printer at
this time as well).
Open the Wager 7500 program by
using the left button on your
mouse on top of the desktop icon
marked "Wagerdcu".
Turn the laptop on.
Location of "ON" button varies.
Please review your computer's
manual, if your unit is different.
Press the Filter Calibration button
and follow on screen instructions.
Turn ON the DCU, press the
RESET button.
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*This system needs to be configured one time only upon initial set
up. In this field you may enter company name, telephone number,
test location, date, etc.. It is important that you enter your DEIC
number at this time.
To access this, press the System Configuration button on step 6, and
Save settings. After saving settings, a pop up diolog box will appear.
Click REPLACE and the press the back button until you return to the
main menu.
If you have purchased a complete system including the lap top
computer, your comm port has already been preset by the factory.
Please do not change this number.
If you have purchased the basic system and are using your own lap
top computer, please contact Wager so that we may assign a
comport number for you.
QUICK START INSTRUCTIONS

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SNAP ACCELERATION TEST

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Test Messages
Test Invalid
This indicates that one of the following test criteria was not met:
Preliminary Spread: Difference between the highest and lowest PSAT was greater than 5%.
Spread: Same as above but during the SAT.
Oil Temperature: Oil temperature was not at the minimum operating temperature of 140°, and the engine
coolant temperature was below 180 degrees.
RPM: RPM minimum was equal to zero during the test sequence.
Weather Condition: Ambient temperature was not between 35° and 95°F, and/or above the dew point.
Zero Drift: Was greater than ± 2%.
Test Failed: The computed average opacity value is greater than allowed under SAE J1667 and/or
your state specifications based on the year model of the vehicle.
Performing the Stall Test or Rolling Test
Connect all sensors as described above.
In the Main Menu, select either
"Stall Test" (automatic transmissions) or
"Rolling Test" (straight drive).
All screen prompts are specific to the test performed and will step the user through the respective test
sequence.
Printing Saved Tests The Model 7500 can save numerous test records. Test storage capacity is
limited only by hard drive space. The system default printer will be used to print the test results.
You can print the test by pressing the PRINT button either before you save the test, or immediately after
completion of the test.

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If you need to print only a specific record, go to "Log File Maintenance" in the "Snap-Test Viewer". You
can use the "Search" function, by typing in the identical VIN number needed. When this record is on the
screen, select "PRINT".
An alternate method is to use the scroll buttons
To scroll through the logfile until the needed record is displayed. When the desired record is on the
screen, press the “PRINT" button.
Printer Options: The Model 7500 “Complete” system is shipped with a full-page portable, battery-
operated ink-jet printer, or you may use any printer that will operate in a Windows environment.
The software automatically prints to the Windows operating system default printer.

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Samples of Completed Test Print-Outs
Snap-Idle Test

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Samples of Completed Test Print-Outs
Rolling Test