WAGER RHW Series User manual

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

TABLE OF CONTENT
WARRANTY……………………………………………………………………….…… 1
GENERAL…………………………………………………………………………...……2
SYSTEM PARTS LIST……………………………………………………………...……3
COMPONENT DESCRIPTION………………………………………………………..…4
INITIAL SET UP……………………………………………………………………….…8
SET UP FOR TESTING………………………………………………………………..…9
SNAP ACCELERATION TEST………………………………………………………...10
SNAP ACCELERATION TEST STEPS………………………………………………..11
FILTER VERIFICATION TEST……………………………………………………..…12
SAVE TEST SEARCHES……………………………………………………………….15
TECHNICAL SPECIFICATIONS………………………………………………………16
MAINTENANCE AND TROUBLE SHOOTING………………………………………17

WARRANTY
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, anticipated profits.
1

GENERAL
The Wager Model RHW Series 2 Full Flow Smoke Meter is in full compliance with the
requirements of the SAE J1667 test criteria—the current U.S. standard.
The system’s simple design, portability, and ease of use provide the user an effortless method
to measure diesel exhaust opacity readings with an accuracy of + or – 1 percent. With all
system components being wireless, this eliminates the need for cables and harnesses. The
wireless nature of the system reduces the effort of the operator greatly and also enables the
operator to perform testing and printing without the need to attach and detach devices. RHW
Series 2 provides readings which ensure compliance with local diesel emissions standards,
promotes combustion fuel efficiency, and also indicates if a engine requires maintenance.
The guidelines and rules of the SAE J1667 can be acquired from:
•SAE International
•400 Commonwealth Drive
•Warrendale, PA 15096 Telephone [phone]
or electronically downloaded at:
•www.sae.org
The RHW Series 2 Full Flow enables the operator to enter test information (VIN, customer
address, etc) into the system, reads ambient weather conditions (relative humidity, barometric
pressure, air temperature), performs 3 preliminary and 3 final snap tests using full flow
technology, and outputs all this data for printout on the wireless portable printer.
Throughout this manual HC referrers to hand controller and SH referrers to senor head.
2

SYSTEM PARTS LIST
Description
Part Number
HC Assembly
199-0000
SH Assembly Module
199-0012-BB
Full Flow Yoke Assy
194-0002
Magnetic Band Clamp
194-0005
Transmitter Wireless Assy
199-0164
Receiver Wireless Assy
199-0165
Transmitter Cable Assy
199-0164-2
Receiver Cable Assy
199-0165-2
Charger, SH &HC
199-0005
SH Battery Pack
199-0003
HC Battery Pack
199-0004
.2ND Verification Filter FF
544-0006
Carrying Case
147-0150-2
Extension Pole
147-C0092
Removable Pole
199-0028-7
Pole Bracket Top
199-0028-5
Pole Bracket Bottom
199-0028-6
Xbee Wireless Module
199-0033
Wireless Printer Assy
OM7212-ZB
Charger, Printer
199-0036
Paper Roll
566-0007
R.H.W. Series 2 Full Flow complete system includes the HC, the SH, three wall chargers, a .2 neutral
density verification filter, portable printer, carrying case, and telescopic pole.
3

Hand Controller
The hand controller is a battery powered wireless
device that contains the atmospheric sensors
and is operated using the membrane keypad
in the menu driven operation program.
Charging jack in located on the left side of
the HC.
Sensor Head
The sensor head assembly uses full flow
technology and is attached to the vehicle
exhaust using a band clamp and magnetic
hook. Latches are used to gain access to the
optical lens for maintenance. Potentiometer
screws are located in the optics to perform
adjustment of the optical signal. Charging
jack is located on the underside of the sensor
head module.
Verification Filter
This filter is used during the filter test
and contains a .2 neutral density filer and is
placed flush up against the metal baffle
centered over the hole that is emitting the
green light (transmitter).
4

Power Packs
There are two universal power packs that
are used to charge the HC and SH
and a third one to charge the printer.
Portable Wireless Printer
This wireless printer is battery powered with
the power jack and on/off switch located on the
back of the unit. It uses 45mm thermal paper.
Telescopic Pole
This pole is expandable and is used to raise
the SH above the cab to reach over-the-cab
exhaust pipes. It may have a detachable
mini segment for use on below-vehicle
exhaust systems.
5

Carrying case
The case is used for transportation and
storage of the system and provides
individual compartments for each of the
system components. Lifting the tray reveals
the bottom section.
Pole Brackets
These brackets are used to mount the sensor
head black box module to the telescopic pole.
Note that the bracket in the foreground has a
circular cutout and is used to mate to the
module.
6

INITIAL SET UP
1.
PRESS THE ON / OFF BUTTON TO POWER ON THE METER
2.
PRESS THE A KEY FOR CONFIGURATION
3.
PRESS THE E KEY FOR EDIT TEST FACILITY INFORMATION
4.
USE THE ARROW KEYS AT THE BOTTOM OF THE KEY PAD TO SCROLL
THROUGH EACH LINE AND THE NUM ALPHA KEY TO ENTER NUMBERS.
ENTER IN YOUR TEST FACILITY INFORMATION
5.
ONCE COMPLETE, PRESS THE SAVE KEY
6.
PRESS THE HOME KEY TO RETURN TO THE MAIN MENU
7.
PRESS THE A KEY FOR CONFIGURATION AGAIN
8.
PRESS THE I KEY TO SET TEST OPTIONS
9.
TO CHANGE ANY OF THE TEST OPTIONS, PRESS THE CORRESPONDING
LETTER BUTTON
10.
PRESS THE HOME KEY TO RETURN TO THE MAIN MENU
11.
PRESS THE A KEY FOR CONFIGURATION AGAIN
12.
PRESS THE M KEY FOR DATE AND TIME
13.
TO CHANGE ANY OF THE MENU ITEMS, PRESS THE CORRESPONDING LETTER
BUTTON
14.
WHEN COMPLETE, PRESS THE ENTER KEY
15.
PRESS THE HOME KEY TO RETURN TO THE MAIN MENU
7

SET-UP FOR TESTING
Installation of the Sensor Head
No matter what style of exhaust system your vehicle has, the Full Flow style attaches the same
way. Engage the magnetic hook over the lip of the pipe and fasten the band clamp using the
latch and hair pin. Once the magnetic bland clamp it fastened, loosen the nut and bolt and
rotate the yoke into position so that the beam is centered over the opening of the exhaust and
is about 1-2 inches from the end of the pipe. The full flow head never touches the flow of
exhaust and is best for long duration testing, including tests that are performed using a
Dynamometer. Ensure the beam of light is parallel to the ground.
Caution: Ensure the sensor head has been powered on and self-calibrated before affixing the sensor
head to the exhaust. If you self-calibrate the unit while the sensor head is in the flow of exhaust, the
equipment will see the exhaust, think the exhaust is the normal dust in the air, and call it zero.
8

SNAP ACCELERATION TEST
The R.H.W. Series 2 Full Flow Smoke Meter has been designs in details to meet the specifications of
the SAE J1667.
The HC has a menu driven user interface that will prompt the user to enter required data, depress
required buttons, and guide the user to completion of the snap test.
A snap test is defined as the peak measurement of opacity of a diesel engine when the throttle is
depress so as to enable the engine to run at maximum governed rpm for a duration of 5 – 7 seconds.
Once the snap is completed, release the throttle, and let the engine return to base idle.
Performing this snap test 3 preliminary times will enable the user to perform the 3 final snaps. The
spread of the tests is calculated by subtracting the smallest measurement from the largest measurement.
The preliminary spread must be less than 5% to perform the final snaps and the final spread must be
less than 5% to be a valid test. Once all preliminary and final snaps are performed, the system will
average the 3 finals snaps and output the average as the result of the snap acceleration test.
9

SNAP ACCELERATION TEST
1.
FROM THE MAIN MENU, PRESS THE M KEY TO ENTER THE SNAP
ACCELERATION TEST.
2.
USING THE KEYPAD, ENTER THE VEHICLE INFORMATION. USE THE ARROW
BUTTONS TO SCROLL EDIT DATA.
3.
START ENGINE.
4.
PRESS THE ENTER KEY TO BEGIN TEST.
5.
ENSURE THE SENSOR HEAD IS NOT IN THE STACK AND PRESS THE ENTER
KEY.
6.
AFTER CALIBRATION IS COMPLETE, ATTACH SENSOR HEAD TO STACK WITH
MAGNETIC BAND CLAMP. PRESS ENTER TO START THE TEST.
7.
DEPENDING ON WHETHER YOU HAVE THE 3 PRELIMINARY SNAPS ENABLED,
YOU WILL BE PROMPTED TO RUN THOUGH A SERIES OF 3 OR 6 SNAP TESTS.
FOLLOW THE INSTRUCTIONS IN GREEN.
8.
THE SPREAD OF THE PRE-SNAP TEST MUST BE WITHIN 5% IN ORDER TO
CONTINUE TO PERFORM THE ACTUAL OPACITY TEST.
9.
AT THE END OF THE SERIES OF SNAP TESTS, TURN THE ENGINE OFF AND
REMOVE THE SENSOR HEAD FROM THE STACK
10.
PRESS THE ENTER KEY TO PERFORM THE ZERO DRIFT TEST
11.
AFTER THE ZERO TESTS IS PERFORMED, IT WILL AUTOMATICALLY STORE
THE TEST RESULTS. YOU CAN PRINT RESULTS TO THE WIRELESS PRINTER.
10

The system comes from the factory with a .2 neutral density verification filter. The filter has a known
value of opacity. This opacity value is stored in the system and is used to verify the system is
functioning properly. On a periodic schedule, run the filter test from the main menu. Follow the
instructions displayed on the HC. Once the filter test is complete, the program will indicate if the
system is reading opacity within tolerance of the filter value.
NOTE: Each filter is unique and has its own value. If you have multiple systems at your location,
keep each filter assigned to its original meter. If you swap filters from one system to another, the filter
verification test may fail.
NOTE: The full flow system does not include a zero filter. When the system prompts the user to insert
the zero filter, just ensure that the sensor head is not in the flow of exhaust and that the band clamp is
not blocking the beam.
Ambient Conditions Calculator
The HC has ambient conditions sensors located on the bottom side of the HC. These sensors record air
temperature, relative humidity, and barometric pressure. The user has the ability to enable or disable
ambient corrections on the measured opacity. If the user enables ambient correction, then the printout
will display the corrected opacity value.
Printing Saved Tests
The system can store up to 128 tests. There are multiple ways in which you can search for and print
stored tests. Power on the unit and select Saved Test Searches from the main menu. The user can
search for last record, record number, company name, plate number, or inspector. Enter the first few
letters or numbers and then press enter. The system will search the database and display all records
that match the search parameters. Then select the appropriate record you wish to print.
11

Below is an example of aprint out that will come from the wireless
printer.
07:58:23PM MM/DD/YY Timeout is Enabled
Revs. HC = X.XX SH = X.XX
12

pSAVE TEST SEARCHES
1.
FROM THE MAIN MENU, PRESS THE I KEY TO ENTER THE SAVE TEST SEARCHES
OPTION
2.
ENTER A LETER CORRESPOINDING TO THE SEARCH YOU ARE TRYING TO PERFROM.
3.
FOLLOW THE INSTRUCTIONS IN GREEN. ONCE COMPLETE, PRESS THE ENTER KEY.
4.
USE THE ARROW KEYS TO SCROLL THROUGH TO THE DESIRED TEST. PRESS THE
ENTER KEY TO SELECT
5.
ONCE ENTERED, YOU CAN PRINT THE INFORMATION TO THE WIRELESS PRINTER
6.
PRESS THE HOME KEY TO RETURN TO THE MAIN MENU.
13

TECHNICAL SPECIFICATIONS
The R.H.W. Series 2Full Flow Smoke Opacity Meter meets the SAE J1667 specification for diesel
emission testing.
Accuracy
The system is designed to be accurate within +or – 1.0% opacity. The control unit self calibrates each
time it is powered onunder clear stack conditions with self tests at 0% and 100%.
Ambient Conditions
Normal operating temperature ranges from 32^ to 120^ F(0^C to 50^C). Ambient corrections of the
measured opacity can be enabled or disabled prior to testing. If ambient corrections are enabled, the
unit will output the corrected opacity reading.
Reliability
Zero stability at less than 1% drift per use.
The backlit TFT display boasts of over 20,000 hours life span.
Optics being pulsed instead of steady on provides extended life of the light source.
Carrying /storage case made of heavy grade material has alife time warranty.
All solid state and state of the art electronics.
Applications
The system is designed for use on any diesel engine, either off-road or on-road, to determine the
engines particulate matter (soot).
Functional Description
Powering!on!the!unit,!the!operator!is!found!at!the!main!menu!of!the!software.!Selecting!the!snap!
acceleration!test!option,!the!HC!searches!the!data!base!for!the!current!testing!location!
information.!At!this!point!the!HC!also!searches!the!wireless!channel!to!detect!other!devices!(SH,!
printer)!and!initializes!communications.!During!the!snap!test,!the!unit!self-calibrates,!testing!0%!and!
100%!limits!and!then!emits!a!pulsed!light!beam!across!the!width!of!the!full!flow!yoke.!The!system!
knows!how!much!light!is!being!emitted,!knows!how!much!light!is!being!received,!and!calculates!
the!difference!and!displays!%!opacity.
14

MAINTENCE & TROUBLESHOOTING
The RHW Series 2Full Flow is built around the most current technology and high grade components.
All parts have a1year factory warranty so if the unit is new, do not attempt to alter or replace any of
the parts without consent of thefactory asthis may void thewarranty.
As with all electronic systems, do not use when inclement weather is present. Also keep all parts from
water.
Charging
The two universal chargers for the SH and HC are interchangeable and can be used on either of these
devices. When connected, the LED indicator light on the charger will show green when the battery is
half charged to fully charged, and will show red when charging from a deeply discharged battery. Do
not attempt to replace any of the battery packs with a non-factory replacement.
The printer charger is specific for the printer only. It is labeled “PRINTER”. Do not use the printer
charger to charge the HC or SH. Both theprinter and printer charger have LED indicator lights. On the
charger, the light will be green when it is plugging into the wall. On the printer, the led will flash when
the charger is connected to theprinter. After thecharger determines thebattery requires charging, the
led ontheprinter will turn to solid red. Once thebattery is fully charged, the ledontheprinter will turn
solid green.
Filters
The zero filter isclear conditions onthesensor head. Ensure themagnetic band clamp is not blocking
the beam and that the sensor head is not attached to thevehicle when you are asked to insert the filter.
The reference (verification) filter contains a 12.5mm diameter piece oftinted glass. If during thefilter
verification test, the filter is reading higher than normal, most likely the filter glass is dirty and
requires cleaning with a small dry cloth or q-tip. If during thefilter verification test, the filter is reading
lower than normal, most likely thefilter glass has degraded and would need to bereturned to the
factory for recertification.
OPTICS SET
The set consists of the transmitter and receiver. The transmitter has 6pins and the receiver has 5 pins.
It is best to periodically clean the lenses with a dry clean cloth. Depending on use, you may have to
clean the lenses daily. There are adjustment potentiometers in the optics that adjust the gain of the
digital signals. Note :do not adjust these without contacting the technical support as you can render
your meter inoperable.
15

OPTIC CABLES
These head duty cables are used to connect the transmitter /receiver to the wireless sensor head black
box module. The cables are keyed so they cannot be connected incorrectly
Sensor Head Black Box Module
The sensor head module is a sealed unit and nomaintenance is required for theoperation ofthemeter.
Ensure the battery is fully charged as indicated by the Led on the charging unit.
Zero Drift
The zero drift is aprocedure to ensure that lenses are not being soiled during atest. Prior to the
preliminary snaps, the meter measures zero opacity. At the end of the three final snaps, the meter
directs the user to turn the engine off and remove the sensor from the stack. NOTE: if you only turn off
the engine and donot remove thesensor from thestack, there are still hot gases rising. So you may fail
the zero drift. So after you have turned off theengine and removed thesensor from thestack, the meter
measures zero opacity again. Now the meter will compare the initial zero to the ending zero. To pass
the zero drift procedure, the difference between theinitial zero and theending zero cannot be greater
than 2%opacity. If you are continuously failing the zero drift, there are certain steps to determine the
cause.
First, run asimulated test. Leave the sensor head on atable or bench and run asnap acceleration test
without the sensor head on the vehicle. All preliminary snaps, all final snaps, and the zero drift should
be zero or close to zero. If any of the readings are greater than 2%, this indicates something is
defective and contact your vendor. If all the readings are zero or close to zero, this indicates that the
meter is working properly and the most likely reason you are failing the zero drift is that the lenses are
being coated by soot. In this case, clean the lenses before you start the test and also asecond time at
the point where it says “turn off theengine and remove thesensor from the stack”. So turn off the
engine, remove the sensor from the stack, unclip the optics one at a time, clean the lenses, re-attaching
both optics, and then press enter to perform the zero drift test.18
Invalid Test
The number one cause for an invalid test is thespread. The spread is thedifference in thehighest
reading and the lowest reading and cannot exceed 5% opacity. For example, on the preliminary snap
readings of 24%, 18%, 12%, the spread will be 24-12=12%. So this will be an invalid test as the spread
is greater than 5%. To eliminate this spread failure, ensure thevehicle is at normal operating
temperature, and perform a few blowout snaps prior to performing theinspection test, then attach the
head and perform the test.
16

Pass/Fail
Each state or country uses different values for different vehicle years to determine if thevehicle is
emitting soot in excess of the limits set by the local guidelines. The RHW Series 2Full Flow does not
determine if the vehicle passes or fails aemission test. It is upto theuser to know thelocal regulations
and use the average opacity printed out on a valid test report to compare this result with values stated in
thelocal regulations.
Printer
To replace the paper in the printer, raise the smoke colored lid to expose the paper trough. Remove the
empty spool and grooved shaft. Discard the empty spool, insert the grooved shaft into the new paper
roll and apply the shaft/spool into the trough. Ensure the paper is feeding from the bottom of the trough,
up towards thefront of theprinter. Close thelid and tear off theexcess paper.
Case
The case is made of amodern material and comes with alifetime limited warranty. It is pretty much
indestructible under normal use and requires little ornomaintenance.
Pole
The telescopic pole, removal pole, and pole brackets are used to position the sensor head to the
exhaust. To elevate the sensor head, use both the telescopic and removal poles. Turn the locking rings
counter-clockwise to release the lock, and extend the pole up. Once at the desired height, turn the
locking rings clockwise to lock. Raise the sensor head above the exhaust and lower the magnetic hook
onto the lip of the exhaust. Secure thesensor head with theband clamp and have a person hold thepole
during the test to ensure thehead is not ejected from theexhaust and becomes damaged.
To lower the sensor head to behind vehicle exhaust system, remove the telescopic pole to shorten the
wand. Use the removable pole to position the SH and nozzle into the exhaust pipe.
17

Wireless Channels
The system communicates via wireless signals that operate on distinct channels labeled C – N.
All devices that are considered a system all must be assigned to the same channel. So if the HC is on
channel H, the SH and printer must also be assigned to channel H.
The user can run an energy scan to inspect the local environment to see which channel provides the
best communication. Running the energy scan displays each channel and the signal to noise ratio and
the higher the number is better.
Once you determine which of the channels is best, change the devices in a specific order to the new
channel. Change the channel of the printer first, then the SH, and lastly, change the channel of the HC.
If you change the HC channel first, the HC will not be able to see the SH nor the printer, because they
are still on the old channel.
The energy scan needs only run if you are having communication issues.
18