500-1000 CFM Conditioner

Model # 9354-6156-B000
(Version 1.0)
Operator’s Manual
Customer Al Taawon
Serial # 1306231
Ship Date October 2013

Parameter Generation and Control, Inc.

P. O. Box 129 1054 Old US 70 West Black Mountain, NC 28711
Phone: (800) 438-5494 Fax: (828) 669-6928
International Phone: +1 (828) 669-8717
PGC Inc. 500-1000 CFM Conditioner Model # 9354-6156-B000 October 2013

Important Information for the User

Intended Use of the Equipment
The 500-1000 CFM Conditioner is designed to control the air temperature from 5°C
(41°F) to 45°C (113°F) and relative humidity (Rh) of 20% to 90%.

Warranty Description
The standard warranty period for this equipment is 12 months from the date of shipment
from our factory, unless otherwise advised in writing. All warranty claims must be
verified as having occurred within the warranty period, and that the conditioner has not
been misused or improperly modified or repaired. When filing a claim, include the
conditioner model number and serial number, which can be found printed on the data-
plate, which is adhered to the conditioner.

Note About This Manual

The contents of this manual are subject to change without notice. If you have questions or
comments about this manual, please contact Parameter Generation Control, Inc. at

Parameter Generation and Control, Inc.

P. O. Box 129 1054 Old US 70 West Black Mountain, NC 28711
Toll Free: (800) 438-5494 Fax: (828) 669-6928
Phone: +1 (828) 669-8717
technical@humiditycontrol.com

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PGC Inc. 500-1000 CFM Conditioner Model # 9354-6156-B000 October 2013

Table of Contents:

Important Information for the User..................................................................................... 2

1. INTRODUCTION .......................................................................................................... 5
1.1 About This Manual ................................................................................................... 5
1.2 Safety and Cautions .................................................................................................. 5
1.3 Data Plate .................................................................................................................. 5
2. Receipt of the PGC Conditioner ..................................................................................... 6
3. Unpacking the PGC Conditioner .................................................................................... 6
4. Placing the PGC Conditioner .......................................................................................... 7
5. Utilities Connections for the PGC Conditioner .............................................................. 8
5.1 Electrical Connections .............................................................................................. 8
5.1.1 Main Power ........................................................................................................ 8
5.1.2 Installation of HygroClip2-S Temperature and Humidity Sensor ..................... 9
5.2 Plumbing and Drain Connections ........................................................................... 10
5.2.1 Water Source Connections ............................................................................... 10
5.2.2 Drain Connections ........................................................................................... 10
5.2.3 Filling and Draining ......................................................................................... 11
5.3 Ducting Connections ............................................................................................... 11
6. Starting and Running the PGC Conditioner.................................................................. 12
6.1 Quick-Start .............................................................................................................. 12
6.1.1 Smart Pad™ Display Screen ............................................................................ 12
6.1.2 Changing Set Points ........................................................................................ 12
6.2 Operation Following Loss of Electrical Power ....................................................... 13
6.3 Equipment Protection Devices ................................................................................ 13
6.4 Equipment Operating Faults ................................................................................... 14
6.4.1 Over Temperature Thermostat ......................................................................... 14
6.4.2 Low-Water Limit Switch ................................................................................. 14
6.5 Equipment Protection Devices ................................................................................ 14
6.5.1 Air Heater Thermal Cut-Out Switch ................................................................ 15
6.5.2 Compressor Internal Overload ......................................................................... 15
6.5.3 Power Supply Fuse .......................................................................................... 15
6.6 Process Variable Limit Alarms ............................................................................... 16
6.7 Changing Control Modes ........................................................................................ 16
7. Taking Care of the PGC conditioner ............................................................................ 18
7.1 Saturator Bypass Damper Test Procedure .............................................................. 19
7.2 Automatic Damper Motor Adjustments.................................................................. 19
7.3 Damper Adaptation Procedure:............................................................................... 20
7.4 Spray Nozzles ......................................................................................................... 20
7.5 Sump Cleaning ........................................................................................................ 20
7.6 Blower Cleaning ..................................................................................................... 21
7.7 Air Cooled Condenser Cleaning ............................................................................. 21
7.8 Air Filters ................................................................................................................ 21
7.9 Water Particulate Filter ........................................................................................... 22
7.9.1 Water Particulate Filter Replacement Instructions. ............................................. 22
8. How the PGC Conditioner Works ................................................................................ 23
8.1 Air Temperature Control......................................................................................... 23
8.2 Saturator Bypass Damper ....................................................................................... 23
8.3 Relative Humidity Control ...................................................................................... 24
8.4 Saturator Temperature Control ............................................................................... 24
9. Fixing Problems with the PGC Conditioner ................................................................. 26
9.1 Failure to Control .................................................................................................... 26
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9.2 Air Temperature ...................................................................................................... 26
9.3 Water Level ............................................................................................................. 27
9.4 Heater Resistance Test ........................................................................................... 28
9.5 Rh Control............................................................................................................... 28
9.6 Water Temperature ................................................................................................. 29
10. Calibrating Control Sensors ........................................................................................ 30
10.1 Exchange ............................................................................................................... 30
10.2 Calibration in an Independent Chamber ............................................................... 30
10.3 Air Temperature and Humidity Calibration Procedure ........................................ 31
10.4 Air Calibration ...................................................................................................... 31
10.5 RH Calibration ...................................................................................................... 32
10.6 Water Temperature Calibration ............................................................................ 33
11. Factory Settings .......................................................................................................... 34
12. Specifications for the PGC Conditioner ..................................................................... 35
13. Parts List for the PGC Conditioner ............................................................................. 36
14. Warranty ..................................................................................................................... 38

Flash drive Contains PDF of this manual and SmartLog

data logging installation files

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PGC Inc. 500-1000 CFM Conditioner Model # 9354-6156-B000 October 2013

1. INTRODUCTION
1.1 About This Manual
This manual is written for the purpose of helping the user gain familiarity with the
installation, operation and basic maintenance requirements of their PGC conditioner. The
manual is divided into numbered sections and sub-sections. A table of contents lists all of
the numbered sections and sub-sections for easy navigation.

1.2 Safety and Cautions

When operating, maintaining or repairing PGC equipment, always be aware of the safety
of yourself and others. The recommended procedures and practices in this manual are
issued for the purpose of providing guidance only, and should not take precedence over
local laws or regulations.

Cautions, Warnings and Notes

At the beginning of certain sections and sub-sections, there will be advisory boxes
labeled, ‘WARNING’, ‘CAUTION’ or ‘NOTE!’

WARNING: An advisory box with this message means that if the

procedures listed in the manual are not followed then bodily injury or
death could occur.

CAUTION: An advisory box with this message means that if the

procedures listed in the manual are not followed, then damage to the
conditioner or associated equipment could occur.

NOTE: An advisory box with this message means that the

supplementary information provided within can help prevent or diagnose
problems with the conditioner.

1.3 Data Plate

The data plate (Image 1.0) contains important information
regarding the PGC conditioner including, model number, serial
number, ship date, voltage requirements, and electrical service
requirements. The data plate can be found adhered to the
chassis of the PGC conditioner. The location varies depending
on the conditioner.

Image 1.0

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PGC Inc. 500-1000 CFM Conditioner Model # 9354-6156-B000 October 2013

2. Receipt of the PGC Conditioner

The PGC conditioner has been securely packed inside a wooden crate for shipping.
Inspect this crate for any signs of damage or mishandling. The crate is equipped with a
liquid tilt indicator that will tell you if the crate was ever tilted on its side or upside down.
The crate should never be tilted on its side or upside down during shipping. If you see
any signs or improper shipping/handling, please contact the shipping provider to file a
claim. Also, please contact PGC to report the extent and nature of the shipping/handling
damage.

3. Unpacking the PGC Conditioner

Prior to unpacking the PGC conditioner, you may want to have the crate moved into a
position near the location where the conditioner will be operating. The packing crate is
held together with Quick-Crate® latches. Unlatch the Quick-Crate® latches and carefully
remove the tops and sides of the crate away from the conditioner. The conditioner will be
sitting on top of a wooden pallet. PGC conditioners are extremely heavy and complicated
pieces of machinery. A forklift or other hoisting device should be used to move the
conditioner from the pallet to the location where it will be operating. PGC strongly
advises against attempting to move one of its conditioner by hand. Dropping a PGC
conditioner will result in serious damage to the conditioner and any damage resulting
from improper handling of the conditioner is not covered by the warranty. Do not drop or
mishandle the PGC conditioner.

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4. Placing the PGC Conditioner

The conditioner should be located in a position close to the required electrical and
plumbing. Also, the access panels for the mechanical compartment, electrical
compartment and chamber door should not be obstructed. The conditioner should be
located on a flat and level surface so that the water level inside the sump will be correct.
Refer to (Image 4.0) for a placement layout diagram.

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5. Utilities Connections for the PGC Conditioner

CAUTION: Do not try to start the PGC conditioner before all of the
necessary connections have been made.

5.1 Electrical Connections

5.1.1 Main Power
This chamber requires a 380V~ ±10%, 3 Phase, 50 Hz power connection.

WARNING: This conditioner must be connected to a grounded

electrical connection.

CAUTION: Turn all electrical switches and circuit breakers off in order
to prevent accidental starting of equipment when power is connected.

NOTE: Determine voltage and current requirements of equipment before

making electrical connections. This information is on a data plate
attached to the machine.

This system is provided with a mains power connection terminal block in the electrical
enclosure on the conditioner. Power should be supplied to this terminal block (three
phases and ground) from an appropriately protected disconnecting device. Examples of
an appropriate disconnect device are a fused safety switch or a plug/receptacle with
proper branch circuit protection. Refer to the electrical schematic, data plate, and
specification sheet for additional connection information.

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PGC Inc. 500-1000 CFM Conditioner Model # 9354-6156-B000 October 2013

5.1.2 Installation of HygroClip2-S Temperature and Humidity Sensor

.
Image 5.1 Image 5.2

Care should be taken when installing the HygroClip2-S sensor to the sensor extension
cable. The HC2 series sensor uses a keyed connector, which is located at the end of the
cable connected to the sensor body (Image 5.1: two small depressions on top and one
larger depression on bottom indicated by arrows). The sensor cable connector (Image 5.2-
Arrow 1) is secured to the HygroClip sensor (Image 5.2-Arrow 3) with a threaded collar
(Image 5.2-Arrow 2). Gently insert the sensor into the connector on the sensor cable. DO
NOT ROTATE THE SENSOR. After the sensor is inserted rotate the threaded collar to
secure the sensor.

Temperature and Rh Sensor Installation

Image 5.3
The HygroClip T/Rh transmitter is routed into the conditioned room through the ceiling
and mounted as shown in (Image 5.3).

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PGC Inc. 500-1000 CFM Conditioner Model # 9354-6156-B000 October 2013
5.2 Plumbing and Drain Connections
5.2.1 Water Source Connections
This chamber requires a Process Water connection. Connect the clean water source to
the ½” male NPT fitting on the rear of the conditioning unit. Refer to Image 5.4 for
connection location. The chamber will not operate without process water. A low water
safety switch will disable the chamber operation if the water level in the sump falls below
a safe operating level.

5.2.2 Drain Connections

CAUTION: Keep the unit drain valve closed while filling the sump
and
 Thewhile the conditioner
Condensate is inaoperation.
Drain has ½” nominal copper tube connection.
 The Unit Drain is fitted with a ¾” Female NPT ¼ turn ball valve (Image 5.4).
This drain should remain closed during chamber operation. This drain can be
opened to drain sump for periodic maintenance and cleaning.
 The Condensate Drain must be connected to a vented drainage hose or placed
above a drainage source (Image 5.5).

Image 5.4

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PGC Inc. 500-1000 CFM Conditioner Model # 9354-6156-B000 October 2013

Image 5.5

5.2.3 Filling and Draining

CAUTION: The conditioner must be located on a level surface for the
automatic float valve to function properly.

Before attempting to operate the conditioner:

 Make sure there is water in the sump. If there is no water in the sump, damage to
the water pump and other components can occur.
 Close the unit drain hand-valve to prevent water from draining from the sump.
 Open the PROCESS WATER INLET hand-valve (not provided by PGC) to fill
the sump with water.
o The sump is equipped with a float valve that will automatically shut off
the PROCESS WATER INLET water flow when the proper sump water
level has been attained.
 Leave the PROCESS WATER INLET water cut-off valve in the OPEN position,
so that if the water level in the sump drops, the float valve can allow more water
to fill the sump and prevent damage to the conditioner.

To drain the sump:

 Close the PROCESS WATER INLET hand-valve
 Open the unit drain hand-valve.

5.3 Ducting Connections

PGC conditioners that control the environment inside a separate room require ducting
connections. The conditioner has a supply connection and a return connection. The size
of the duct required will vary depending on the PGC conditioner purchased. The ducting
coming from and going into the separate conditioned room or chamber should create a
loop with the conditioner. Connect one duct from the supply side of the PGC conditioner
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PGC Inc. 500-1000 CFM Conditioner Model # 9354-6156-B000 October 2013
to the conditioned room or chamber. Connect the other duct from the return side of the
PGC conditioner, to the conditioned room or chamber. The dimensional drawings located
in the manual binder will show a diagram of the ducting connections. MAKE SURE
THAT ALL DUCT CONNECTIONS ARE TIGHT AND DO NOT LEAK ANY AIR.

6. Starting and Running the PGC Conditioner

NOTE: The Smart Pad™ user interface interconnection cable has a
maximum voltage of 24VDC. Refer to local codes to determine the
proper conduit requirements for the control cable.

The optional circular chart recorder can be powered by 24VDC or

line voltage. Refer to the wiring diagrams or the data plate on the
recorder for more information.

Once all of the required connections for the PGC conditioner have been made, the
conditioner can be started.

6.1 Quick-Start

The SmartPad user interface on the PGC conditioner must be

configured for Run mode and will automatically operate when the
cycle control provides the run command. The cycle controller will
automatically energize each conditioner as determined by the cycle
frequency.

6.1.1 Smart Pad™ Display Screen

The Smart Pad™ screen will display the actual measurements of a

combination of values depending on the type of PGC conditioner
Image 6.0 you purchased and the operating mode of the system. This is called
the PROCESS VARIABLE DISPLAY

6.1.2 Changing Set Points

The bottom of the Smart Pad™ screen will display various options above the four
function keys, which comprise the top row of the Smart Pad™ keypad (F1, F2, F3, and
F4). The function keys will operate and change different settings and aspects of the Smart
Pad™ and the conditioner depending on which screen is being viewed. The actual air
temperature/relative humidity/water temperature screen (the first screen displayed after
starting the conditioner from Standby mode) will show SP above the F2 key. Pressing the
F2 key will change the Smart Pad™ to the set point screen, where the air temperature and
relative humidity (RH) or air temperature and water temperature set points can be
changed. The Smart Pad™ screen will show a blinking cursor next to the largest digit in
the air temperature set point value; to change this value, type in the desired air
temperature set point without using any decimal points.

In order to enter a value that is equal to or greater than 10 and has a zero in the decimal
place, type the first two digits and then zero into the Smart Pad™. For example, to enter
11°C as a set point, type 1-1-0 into the Smart Pad™.

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PGC Inc. 500-1000 CFM Conditioner Model # 9354-6156-B000 October 2013
The Smart Pad™ keypad does not include a decimal point button. In order to type in a
value less than 10 with a decimal value greater than zero, first type a ‘0’ then the desired
number. For example, 8.3°C would be typed as 0-8-3.

After filling all the possible spaces in the field the cursor will return to the left side of the
largest digit in the field and it is at this point that the set point value has been entered into
the system. In order to scroll down to the relative humidity or water temperature set point
field, select the TAB option by pressing the F1 key. The cursor will move down to the
left side of the largest digit in the relative humidity (RH)/water temperature set point
field. Enter the desired set point into the relative humidity (RH) set point/water
temperature set point field in the same way as described for the air temperature set point.
The PGC conditioner will now run at the desired parameters.

6.2 Operation Following Loss of Electrical Power

If there is a power outage and the PGC conditioner shuts down, it will restart in the same
mode as before the power outage. For instance, if the Smart Pad™ was in standby mode
when power was lost, it will be in standby mode when power is restored. If the Smart
Pad™ was operating and controlling the chamber, it will return to that mode of operation.
If the system was running a program via SmartLog, the program will restart at the last
saved segment and segment countdown time when power is restored.

6.3 Equipment Protection Devices

WARNING SYMBOLS

Protective Ground

DC Current
AC Current

Risk of Electrical Shock

Hot Surface

Warning

Rotating Parts Hazard

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PGC Inc. 500-1000 CFM Conditioner Model # 9354-6156-B000 October 2013
6.4 Equipment Operating Faults
NOTE: Some faults will clear automatically and others will require user
intervention. Regardless of the fault clearing mechanism, the user must
press the Standby key in order for the conditioner to resume operation.

The PGC conditioner is equipped with a wide variety of equipment protection devices
that prevent damage to the conditioner. There are some equipment protection devices that
will cause the conditioner to enter a FAULT status, during which time the conditioner
will stop operating. When the cause of the fault has been corrected, the conditioner will
be capable of restarting. When a fault occurs, the Smart Pad™ screen will display a
message indicating that the system has entered a fault status, the kind of fault and that the
fault must be cleared prior to restarting the conditioner. Once the cause of a fault has
been cleared, the conditioner can be restarted in the same operating mode and parameters
as before the fault. Press the Standby key to restart the conditioner after a fault status
occurs.

6.4.1 Over Temperature Thermostat

The Over Temperature Thermostat (Image 6.1) has a dial
type switch located near the process blower motor. This limit
thermostat is designed to protect the contents of the test
chamber from excessive temperature rise in the event of a
system failure. The operator may set the dial on the
thermometer manually in order to protect the product under
test, normally 2-3°C (5°F) degrees above highest test
temperature. If this thermostat opens due to excessive
temperature, the conditioning unit will shut down and the
Smart Pad™ user interface will indicate “TEMPERATURE Image 6.1
FAULT SET”. The thermostat will automatically reset when
the temperature inside the chamber drops below the cut-out temperature. After the
thermostat has reset, the Smart Pad™ user interface will indicate “TEMPERATURE
FAULT CLEAR”. The alarm output can be reset by pressing the Standby key on the
Smart Pad™ key pad.

6.4.2 Low-Water Limit Switch

A low-water level limit float switch is located in the sump. If the water level drops below
a safe operating level the switch will shut down the air handler. The Smart Pad™ user
interface will indicate “LOW WATER FAULT SET”. The float switch will automatically
reset when the water level in the sump returns to a safe operating level. After the switch
has reset, the Smart Pad™ user interface will indicate “LOW WATER FAULT CLEAR”.
The alarm can be reset by pressing the Standby key on the Smart Pad™ key.

6.5 Equipment Protection Devices

The PGC conditioner is also equipped with equipment protection devices that will disable
the air handler to prevent damage to the system. If an equipment protection device is
engaged the system will shut down completely. No indication will be provided on the
SmartPad user interface.

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PGC Inc. 500-1000 CFM Conditioner Model # 9354-6156-B000 October 2013
6.5.1 Air Heater Thermal Cut-Out Switch
The air heater thermal cut-out switch will disable the entire
system if the temperature near the air heaters exceeds 105°C
(221°F). (Image 6.3) This thermostat will automatically
reset when the temperature drops to a safe operating level.

6.5.2 Compressor Internal Overload

The refrigeration compressor is equipped with an internal
thermal protector is located on the front of the compressor.
If the compressor draws excessive current, the motor
windings will overheat. If the windings overheat, the Image 6.3
internal thermal protector will open and the compressor will
not operate. The rest of the chamber will continue to function, although it is not possible
to control air or water temperature unless the compressor is operating. As soon as the
internal temperature of the compressor motor drops to a safe operating level, the
compressor will resume operation. This reset process will normally require about 45
minutes. There are several potential causes of a compressor internal overload, and they
vary depending upon the design of the unit. In units that have a water cooled condenser
some causes of compressor internal overload include the loss of coolant water flow,
excessive coolant water temperature and clogged coolant water inlet filter. High ambient
temperature, excessive refrigerant charge or low line voltage can cause a compressor
internal overload in both water cooled and air cooled units.

6.5.3 Power Supply Fuse

The DC power supply is protected by an internal fuse (Image 6.5).

Image 6.5

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PGC Inc. 500-1000 CFM Conditioner Model # 9354-6156-B000 October 2013
6.6 Process Variable Limit Alarms
The conditioner is also equipped with a user-configurable temperature and Rh process
variable alarm. The alarm can be configured for limits (max/min) or deviation (variation
from set point). If either process variable exceeds the alarm parameters for a user-
defined time delay an alarm condition will occur and the delay counter will activate.
Pressing ACK (F1) on the SmartPad will stop the delay timer. Pressing RESET (F2)
clears the alarm condition and restarts the delay timer.

6.7 Changing Control Modes

The PGC conditioner has been programmed to operate in a variety of different modes
depending on the design of the system. The different modes allow the user to manipulate
different parameters of environmental control within the conditioned room or chamber.
The conditioner can be set to operate in different modes via the Smart Pad™. In order to
view the current operating mode of the conditioner start from the PROCESS VARIABLE
DISPLAY screen described above. Press the F4 button, which will be associated with the
> option on the Smart Pad™ screen. Then press the F4 button again to access the INFO
option displayed on the Smart Pad™ screen. The current control mode will be displayed
on the bottom of the Smart Pad™ screen.

In order to change the control mode of the conditioner, start from the PROCESS
VARIABLE DISPLAY screen. Press the F4 button, which will be associated with the >
option on the Smart Pad™ screen. Then, press the F3 button, which will be associated
with the CONFIG option on the Smart Pad™ screen. The Smart Pad™ will ask for a
security code. The code is ‘0000’. Type the code in using the Smart Pad™ keypad. The
Smart Pad™ will now display the System Configuration screen. Press the F1 button to
access the MODE option on the Smart Pad™ screen. The Smart Pad™ will now display
the CONTROL MENU screen. Press the F3 button, which will be associated with the
Change option on the Smart Pad™ screen. You will see the Control Mode on the Smart
Pad™ screen change. When you have found the control mode you want, press the F4
button, which will be associated with the Enter option on the Smart Pad™ screen. The
new control mode is now entered into the system and the conditioner will begin operating
according to the parameters of that mode. The PROCESS VARIABLE DISPLAY screen
will be displayed again, at which point the set points can be changed in the manner
described above.

NOTE: DO NOT use Dry Mode on this conditioner. This mode will not
function unless the desiccant dryer option has been installed.

CAUTION: DO NOT use Temperature Only Mode with this unit. This
unit is designed to control air temperature, water temperature and Rh.
Using Temperature Only Mode will cause the unit to malfunction.

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PGC Inc. 500-1000 CFM Conditioner Model # 9354-6156-B000 October 2013

This conditioner will only function properly in the following modes:

1. Rh Cascade Mode:
This is the most commonly used mode because the user specifies only the desired
air temperature and relative humidity (Rh) level in the chamber. The temperature
of the water spray controls the dew point of the discharge air and the water
temperature is adjusted in order to achieve desired humidity level. The air is then
re-heated to the desired temperature before returning to the test chamber. This
allows the system to respond to load variations while retaining the basic stability
of a spray system.
2. Two-Temperature Mode:
In this mode, the user establishes the desired air and water temperatures that are
required to produce the desired relative humidity level, as determined by a
psychometric chart. The Two-Temperature mode can be used when operating at
the very edges of the system capabilities.
3. Slow Damper Mode:
This mode is similar to Rh Cascade mode with the difference being that the air
bypass damper control loop and the air heater control loop have been separated.
In this mode the damper is moved slowly and its final position is when the desired
percentage of air heat output is achieved. The desired percentage of air heat is
determined by the user in the tuning parameters (Manual Adjust) section of the
controller. In some situations, slow damper mode can be applied to improve
energy efficiency or extend the operating range of the system. Typically, slow
damper mode is most effective when the system is operated at a single condition
as it will often require manual tuning adjustments for proper operation at multiple
set points.

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7. Taking Care of the PGC conditioner

CAUTION: Only licensed refrigeration service technicians should work
on the refrigeration components of this conditioner. This unit was
initially charged 96oz of R404A.

CAUTION: The hot gas bypass valve may cause a false indication of
low refrigerant charge in the sight glass if the valve is not closed at the
time it is being observed.
This PGC conditioner is designed to run for extended periods of time with minimal
maintenance. However, some basic steps should be taken to maximize the serviceable life
of the PGC conditioner.
Follow these steps to take proper care and ensure optimal performance of this PGC
conditioner:
Component What to Check Periodicity
The blower wheel should be checked periodically for cleanliness.
Blower Wheel A dirty blower wheel may reduce airflow drastically. If the wheel Annually
cannot be cleaned, the blower should be replaced.
Inspect and clean the outside coils. Typical A/C condensers
Condenser,
require less frequent cleaning than PGC air cooled Quarterly
Air-Cooled
condensers because they only operate part of the time.
Check resistance to ground; less than 50KΩ indicates a
Heaters Annually
possible heater failure.
Spray Chamber Drain and flush out the interior (including evaporator coil, Quarterly
spray eliminator, walls and sump) to remove deposits. or as
needed
It is important to periodically change the water. All water
contains some impurities. The spray water also picks up
anything in the air. During normal conditioner operation,
Quarterly
some water vapor is lost. This water is replaced by the
Sump or as
supply. Over time, the concentration of the impurities in the
needed
supply water increases and deposit out on the coils and
other parts of the chamber. Periodic draining and flushing
with clear water will materially reduce such accumulations.
The spray nozzles should be checked periodically to make
sure they are free of foreign particles that might impair their Quarterly
Spray Nozzles operation. The spray pattern may be observed by opening or as
the front access door. All spray jets should be working and needed
spraying uniformly.
Water RTD RTD was calibrated at the factory. Re-calibration should not be
As needed
Calibration necessary.
Air Annually,
Temperature/Rh HygroClip™ must be re-calibrated. or as
Calibration needed
Motors Motors have no oil fittings and require no lubrication. N/A
Zinc Anode The zinc corrodes to protect copper and other materials As needed
inside the process chamber. The zinc should be checked
periodically and replaced when necessary.
Air Filters Air filters collect particulate matter from the air stream and Quarterly,
must be replaced periodically. or as
needed

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PGC Inc. 500-1000 CFM Conditioner Model # 9354-6156-B000 October 2013
7.1 Saturator Bypass Damper Test Procedure

The position of the saturator bypass damper actuator is determined by the air control
loop. When the air output percentage is 100% the damper will be positioned to direct all
of the air around the water spray (full bypass). When the air output is 0% the damper will
direct all of the air through the water spray (full spray).

NOTE: If the controller is configured for slow damper mode,

temporarily re-configure for two-temperature mode

The simplest method to test the damper operation is to change the air temperature set
point in order to force the damper to a known position. Verify that the damper is correctly
positioned for the output percentage and repeat the procedure for the other extreme.

For example: If the measured air temperature is 25°C, Adjust the air set point for 40°C.
This will produce 100% air heat output and drive the damper to the full bypass position.
Verify that the damper is in the correct position. If not, determine and correct the
problem.

Then, adjust the air set point for 10°C. This will produce 0% air heat output and drive the
damper to the full spray position. Again, verify damper position and correct as necessary.

7.2 Automatic Damper Motor Adjustments

The damper actuator has a directional switch that determines the direction of rotation for
the actuator (Image 7.0-Arrow 4). Different dampers will rotate in different directions
depending on mechanical configuration. When replacing a damper actuator the
directional switch must be configured to provide the proper rotation. Use a flat-head
screwdriver to set the switch to the same rotation pattern as the actuator being replaced.

On some conditioning units, the damper is prevented from moving a full 90 degrees. The
damper actuator, however, is designed to permit a full 90 degrees of rotation. The damper
actuator is equipped with mechanical motor stops (Image 7.0-Arrows 1 and 3) that can be
adjusted to limit damper movement according to the specific requirements of the
conditioning unit. These stops must be adjusted to prevent damage to the damper
mechanism.

After adjusting the damper motor stops the motor must be adapted. This process will
allow the microprocessor in the damper actuator to determine the mechanical limits of the
damper and actuator travel. This must be done for proper damper operation.

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PGC Inc. 500-1000 CFM Conditioner Model # 9354-6156-B000 October 2013

7.3 Damper Adaptation Procedure:

a. Adjust the mechanical stops (Image 7.0-

Arrows 1 and 3) to allow proper damper
travel. Press and hold the clutch button
(Image 7.0-Arrow 2) and move the damper.
b. Press and hold the ADAPTION button
(Image 7.0-Arrow 5) until the STATUS
indicator (Arrow 6) is illuminated (the
ADAPTATION button also serves as the
POWER indicator).
c. The actuator will travel to the counter-
clockwise stop and then to the clockwise
stop. The STATUS indicator will remain
illuminated during the adaptation process
(approximately 150 seconds). Image 7.0

Image 7.0

7.4 Spray Nozzles

The spray nozzles (Image 7.1 shows some examples) should be checked periodically to
ensure they are free of foreign particles that might impair their operation. The spray
pattern may be observed by opening the access door. All spray jets should be working
and spraying uniformly.

7.5 Sump Cleaning

It is important to periodically change the
water in the sump. All water contains some
impurities. The spray water also picks up
anything in the air. During normal conditioner
operation, some water vapor is lost. This
water is replaced by the supply via the float
valve. Over time, the concentration of all
these impurities increases and will form
deposits on the coils and other parts of the
chamber. Periodic draining and flushing with
clear water will reduce such accumulations.

Image 7.1

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PGC Inc. 500-1000 CFM Conditioner Model # 9354-6156-B000 October 2013

7.6 Blower Cleaning

The blower motor on this unit can become encrusted with
sediment over time. If the unit fails to maintain an
indicated set point, check the blower motor for
sedimentary build-up. If the sediment cannot be removed
without damaging the fan blades/motor, then the entire
blower motor assembly must be replaced.

7.7 Air Cooled Condenser Cleaning

The air cooled condenser must be periodically cleaned to
prevent excessive accumulation of dust or other
particulate matter. Use compressed air or a vacuum
cleaner to remove any dirt, dust or other obstructions Image 7.2
from the surface of the coil and the condenser fan blade.
(Image 7.3)

Image 7.3

7.8 Air Filters

The air filters are located in the top
compartment (Image 7.4). It is
important to periodically check and
change the air filters in this unit. The
frequency of replacement can vary.
Check air filters often at first and
change as needed.

Image 7.4
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7.9 Water Particulate Filter
The particulate filter is located in the sump and must be operating properly to
reduce
deposits on the interior surfaces of the chamber. Clean or replace the filter on a regular
basis. The replacement frequency of this filter will be determined by each individual
environment. Check the cleanliness of the water after 14 days of run time. If the water is
clean, check again in 14 days. Continue to check the cleanliness until an adequate
schedule can be determined.

7.9.1 Water Particulate Filter Replacement Instructions.

1.) Turn the air handler off.

Image 7.5 Image 7.6

2.) Remove the particulate filter housing from the sump by loosening the
compression fitting that secures the filter housing to the ½” stainless steel tube.
(Image 7.5 Arrow 1 and Image 7.6)

Image 7.7

3.) Remove the cover from the filter housing. (Image 7.7)
4.) Remove the used filter. Typically, the filter must be un-screwed from the
housing.
5.) Install the new filter. Typically, the filter can simply be “pressed” into the
housing.
6.) Replace the filter housing cover.
7.) Re-install the filter housing on the ½” stainless steel tube.

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8. How the PGC Conditioner Works

This PGC Conditioner is designed to control the following parameters

Air is circulated through the conditioner by the blower. The temperature and relative
humidity (Rh) of the air moving through the conditioned space are controlled by air
heaters, a damper system, a refrigeration system, and a saturator system.

8.1 Air Temperature Control

The temperature of the process air stream is measured by the HygroClip 2 temperature
and Rh transmitter, located in the supply duct. This measured temperature is compared to
the user-defined air set point in order to determine the air output percentage. The output
percentage can be viewed on the SmartPad user interface.

The duty cycle (on time vs. off time) of the air heaters as well as the position of the
saturator bypass damper are based on the air output percentage. 100% air output will
energize the air heaters 100% of the time for full heat. 0% will turn the air heaters off
and any value greater than 0% but less than 100% will energize the air heaters a
proportional amount. A red LED on the ACE controller will flash on/off as the heaters
are energized or de-energized. The frequency of the heater output control will cause the
LED to flash faster than the can be visually observed. However, the intensity of the LED
will increase or decrease as the heater output increases or decreases. The heater duty
cycle can also be measured using a commonly found current meter. The amperage
consumed by the heater will increase or decrease proportionally as the output increases or
decreases, which can be observed on the meter.

8.2 Saturator Bypass Damper

The saturator bypass damper will be automatically positioned by the air control output.
When the damper is open (full counter clockwise) air will bypass the saturator. When the
damper is closed (full clockwise) air will enter the saturator. It can be assumed that the
saturator temperature will always be colder than the air temperature; or else the humidity
could be greater than 100%. Therefore, any air that enters the saturator will be cooled as
it passes through the water spray. Any air that bypasses the saturator will not be cooled,
and will therefore require less air reheat to achieve the desired set point. The damper
position is relative to the air output in that increased air output will cause more air to
bypass the saturator.

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PGC Inc. 500-1000 CFM Conditioner Model # 9354-6156-B000 October 2013
8.3 Relative Humidity Control
The relative humidity is measured by the same HygroClip 2 temperature and humidity
transmitter. The measured humidity is compared to the user-defined Rh set point. Based
on this comparison the saturator temperature is slowly increased or decreased until the
desired Rh is achieved in the chamber.

8.4 Saturator Temperature Control

The saturator temperature is measured by a 100Ω, Class A RTD located in the water
plumbing. This temperature is compared to the saturator set point determined by the Rh
control loop. Based on this comparison the water output percentage is determined. This
output percentage can be viewed in the SmartPad User Interface.

The saturator temperature is controlled by circulating water from the sump into the water
pump inlet. The pump discharge line returns the water to the saturator through a series of
spray nozzles and stirring jets. The saturator RTD is located in the water line from the pump
to the spray nozzles. Heat is added to or removed from the water by the refrigeration system.
The evaporator is coil located in the saturator/sump area of the chamber. Air entering the
saturator will pass through the finned coil. Water circulated by the pump will be sprayed into
the leaving air side of the evaporator. The finned surface of the evaporator will remove heat
from the air and water.

The capacity of the refrigeration system is determined by the position of the hot gas bypass
valve. This valve will control the flow of discharge gas from the compressor into the
evaporator, downstream of the expansion valve. When the valve opens the hot gas flow will
increase. Increased hot gas flow will add heat to the evaporator, reducing the heat removal
capacity. Increase hot gas flow will also increase the pressure in the evaporator, causing the
mechanical expansion valve to meter closed and also reducing capacity. Although the
refrigeration system does not function as a heat pump, it does have the ability to add heat to
the saturator. The refrigeration compressor motor is cooled by the refrigerant passes through
the compressor case. This waste heat can be reclaimed, to some extent by the hot gas added
to the evaporator. The position of the hot gas bypass valve is directly proportional to the
water output percentage. 0% output will position the valve in the full closed position
providing maximum refrigeration capacity. 100% output will open the valve completely and
provide minimum refrigeration capacity.

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 PGC Inc. 500-1000 CFM Conditioner Model # 9354-6156-B000 October 2013

Electrical Section
Air Heat
Phase Compressor Pump Circuit
Air Heat Relay Circuit Breaker Circuit
Water Heat Relay Relay Breaker
Breaker

Line Contactor Water Heat

Blower Motor Circuit Breaker
Starter TB1
Control Circuit Condenser Fan
Alarm Breaker
Circuit Breaker

Ace 9 TB4
Board

Mechanical Section

Compressor
Water
Over Temp Sight Glass Hot Gas Valve
Thermostat
Receiver

Pressure Gauge

Condenser

Compressor
Internal Overload
Discharge Port
Pump

Suction Port

Dryer Filter

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9. Fixing Problems with the PGC Conditioner

More often than not, when the conditioner will not perform as expected the problem is
something simple, like a dirty blower, or an improperly sealed panel or door. Always
remember to approach a malfunctioning conditioner in a systemic, step-by-step manner in
order to find the true cause of the problem; otherwise you may end up creating another
problem with the conditioner.

There are a limited number of potential problems that can occur depending on the type of
conditioner purchased. Follow these steps to troubleshoot the PGC conditioner:

9.1 Failure to Control

When the conditioner will not operate at the desired parameters, there are many potential
causes. A basic understanding of the operation of the conditioner will assist in
determining the cause of the problem.

1.) The blower, pump, condenser fan and compressor operate at ALL TIMES. If
any of these items are not operating, it is a problem. Check for motor
overload, failure or loose connections.
2.) In spray mode, the air temperature will always be greater than the water
temperature. Heat is removed from the air only when the air passes through
the water spray.
3.) The water temperature can approach freezing, but it must not be allowed to
freeze; the minimum water temperature is approximately 2.5°C (34.5°F).
Since the dew point is determined by the temperature of the water spray, the
minimum dew point will always be greater than the water temperature,
thereby limiting the minimum achievable dew point.
4.) Ambient conditions will limit operation of the unit. If the room temperature
surrounding the conditioner is too warm or humid, heat cannot be properly
rejected by the air cooled-condenser, affecting the chamber temperature and
humidity.
5.) The conditioning chamber panels are not completely sealed or latched. Check
the condition of the seals around the panels to ensure they are not worn or
broken.
6.) The unit is not properly connected to an electrical power source. Ensure the
unit is plugged in.
7.) The condensate drain is not connected to a vented hose or tube. Make sure the
condensate drain is connected to a vented hose or tube.

9.2 Air Temperature

1.) The conditioner is not properly controlling air temperature:
a. Check the water temperature (set point and measured). If the water
temperature is out of control, it is usually not possible to control the air
temperature.
b. Is the air heater operating properly? Check the air heater current. See
Section 7 for information on testing air heater operation.
c. Make sure the airflow is not restricted.
d. Make sure the blower is operating efficiently. The blower should spin
freely and should be free of sedimentary build up. If there is a good deal of

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PGC Inc. 500-1000 CFM Conditioner Model # 9354-6156-B000 October 2013
sedimentary build up on the blower it must be cleaned or replaced. See
Section 7 for information on cleaning the blower.
e. Make sure the chamber is properly sealed. Are any panels/doors/drawers
properly sealed? Are the gaskets in good condition? Are the seal and panel
latches properly secured?
f. Has the load in the chamber increased or changed in any way? Was
something recently put inside of the chamber or taken out? When
something is placed into or taken out of the chamber the conditioner must
adjust to compensate for the new conditions. Give the conditioner time to
adjust to the new conditions and achieve the desired set-points.
g. Is the conditioner receiving enough voltage? Low line voltage will
drastically reduce the wattage of the air heaters.
h. Is the damper operating properly? Ensure that the damper plate is not
slipping on the motor axle. Make sure the rubber gasket on the damper
plate is in good condition.

9.3 Water Level

1) Is the water backing up into the conditioner/not draining properly?
a. The overflow drain must be properly trapped.
b. The overflow drain must be connected to an open drain. The drain will not work
properly if any back pressure is present.
c. The overflow drain must be functional. If the water level is above the overflow
drain standpipe, the drain is not working properly.
2) The float valve must maintain the proper water level. The proper water level should be
high enough to prevent cavitation of the pump (drawing air into the pump inlet), but
should not be high enough to cause excessive, constant overflow (too much overflow will
overload the refrigeration system

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9.4 Heater Resistance Test
Caution: All resistance measurements must be performed with all
power removed from the chamber. Follow these steps to test the heater
elements using a multimeter tool.
1. To measure the resistance of the heating element:
a. Disconnect the heater lead wires from the circuit. See the electrical schem
atic to determine where the heater lead wires connect to the circuit.
b. Use a multimeter to measure the resistance (Ω) from lead to lead on the he
ater wires.
i. The heater is nothing more than a resistor, therefore the resistance
can be calculated using Ohm’s law (Watts = Volts²/ Resistance). F
or example, if the air heaters in the chamber are 1500 watts at 240
V then the measured resistance should be approximately 38 Ohms
(Ω).
ii. See the electrical schematic to determine the wattage of the heaters
in the conditioner.
c. If the heater is open, the resistance will be very high or will measure as an
open circuit
d. If the heater is shorted to ground it is possible that the resistance will meas
ure less than the nominal value
2. To measure the insulation resistance of the heating element:
a. Disconnect both heater lead wires from the circuit
b. Measure the resistance from each lead wire to earth ground
i. If the measured resistance is greater than 500K Ohms (Ω), then the
insulation resistance is acceptable.
If the measured resistance is less than 500K Ohms (Ω), then the insulation resistance is
unacceptable and the heater should be replaced

9.5 Rh Control
1. The unit is not properly controlling Rh.
2. Ensure the water temperature is controlling properly. If the water temperature is
out of control, the Rh cannot be controlled.
3. Ensure the air temperature is controlling properly. If the air temperature is out of
control, the Rh cannot be controlled.
4. Is the damper operating properly? Ensure that the damper plate is not slipping on
the motor axle. Make sure the rubber gasket on the damper plate is in good
condition.
5. The Rh inside a chamber or room can never be at 0%. If the Rh reading is at 0%,
then the sensor is malfunctioning and should be recalibrated or replaced.

NOTE: The water droplet eliminator must be installed correctly, as

shown in the figure below. Otherwise, droplets will pass through the
droplet eliminator and come into contact with the air heater. This will
cause the droplets to vaporize, resulting in erratic RH control. (Image
9.1)

Water Droplet Eliminator Air Flow Direction

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Image 9.1

9.6 Water Temperature

The refrigeration system controls the water temperature.
1. The water temperature is too high:
a. Check for proper water flow
i. Is the pump operating? Check to see if the motor is spinning. On
some pumps, this can be determined by observing the fan on the
back of the pump motor.
ii. Is the water clean? Check the sump water for dirt and other
impurities. If the sump water is dirty, drain the sump and refill it
with clean water (see Filling and Draining).
iii. Are all of the spray nozzles working? All of the nozzles should
have a similar spray pattern. If the patterns vary, remove the
nozzles and clean the debris from the orifice.
iv. Is the finned evaporator clean and free of debris?
b. Verify the operation of the refrigeration system
i. When the hot gas valve is fully closed the refrigeration sight glass
should be clear. To close the hot gas valve, the water output must be
set to 0%. Switch the system to Two Temperature mode, and then
change the water set point below the actual water temperature until
the water output reads 0%. Check the refrigerant sight glass. Any
bubbles in the sight glass will indicate a low refrigerant charge.
ii. Is the refrigeration discharge pressure too high?
1. The air cooled condenser could be dirty
2. The ambient temperature could be above 2 .4 C ( 5 F)
3. The condenser fan may not be working
c. The heat load in the chamber exceeds the capacity of the system. Since the
heat from the air stream is removed by the finned evaporator and the water
spray, if the heat load in the chamber is too great, the refrigeration system
will become overloaded. The first indication of this is that the water
temperature (and therefore Rh) is higher than requested.).

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10. Calibrating Control Sensors

The control sensors in the PGC conditioner measure the air temperature, relative
humidity and/or water temperature inside the conditioner. Temperature/Rh conditioners
measure air temperature, relative humidity and sump water temperature. These sensors
were calibrated at the factory and should not require recalibration until the recalibration
date on the sensors expires (usually a year from the date of delivery). In order to calibrate
the sensors in the PGC conditioner follow these steps:

10.1 Exchange

NOTE: PGC, Inc. strongly encourages the use of the Exchange

Calibration program. Conducting calibrations on site tends to be
problematic because the conditioner must be taken out of service for the
calibration process and the test conditions are not as well controlled as
they would be in a dedicated calibration conditioner. At PGC, Inc., we
have a dedicated calibration conditioner, which can calibrate sensors with
higher precision in less time.

Both PGC and Rotronic© (the sensor manufacturer) have a sensor exchange program.
Contact Rotronic© for details regarding their plan and calibration schedule; for a nominal
calibration fee, PGC will provide a calibrated temperature and Rh transmitter as often as
you desire. The replacement sensor will be shipped complete with calibration data that
can be used for validation. The returned sensor will be re-calibrated and used as an
exchange sensor in the future. The “as found” data from the returned sensor can be
forwarded to the customer to be used for validation. Contact PGC for current pricing for
this service.

The customer can also purchase a second calibrated transmitter, which can be
interchanged with the original sensor. The original sensor can then be returned to
Rotronic©, PGC, or a calibration laboratory for re-certification. This process can then be
repeated on a schedule determined by the customer’s specific requirements.

10.2 Calibration in an Independent Chamber

The HygroClip2 can also be calibrated through the serial port of a Windows based PC.
An interface cable, available from Rotronic, allows the PC to communicate directly to the
HygroClip2. The HygroClip2 is then positioned in a stable chamber, compared to a
reference standard, and adjustments made to the calibration constants from the PC.
Contact Rotronic or PGC for more details regarding PC based HygroClip2 calibration.

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10.3 Air Temperature and Humidity Calibration Procedure

The calibration menu is protected by the advanced access code. The user is strongly
encouraged to carefully read the procedures for calibration before attempting to use
any feature in this menu.
There are four possible calibrations that may be performed from the Smart Pad™: air
temperature, relative humidity, water temperature, and auxiliary temperature. The air and
RH calibrations are performed by means of direct communication with the calibration
parameters stored inside the Rotronic HygroClip2 sensor. The Smart Pad™ cannot
calibrate any other air/RH sensor directly. The Smart Pad™ is capable of a single point
air calibration and up to 100 RH calibration points. In addition, both air and RH
calibrations may be restored to default factory calibration values.

10.4 Air Calibration

The air temperature is provided by the Rotronic HygroClip2. Though the HygroClip2
allows for multiple point air calibration using one of its calibration interfaces, such as the
HF2, only a single point calibration may be performed from the Smart Pad™.
To adjust the temperature reading in the HygroClip2, operate the unit until it is stable.
Once stability has been reached, read the value from the reference sensor and enter it into
the Ref. Value field. Press F3 to adjust the reading. A warning message will prompt the
user to continue or abort. When OK is pressed, the calibration will be sent to the
HygroClip2. In several seconds, the Air Actual value should change to equal the
reference value.

F1 ERASE Restore air calibration to factory

calibration default (Rotronic
AIR CALIBRATION calibration) values
Air Actual 22.7ºC
Ref. Value 22.5ºC F2 No function
ERASE ADJUST ESC ADJUST
F3 Adjust HygroClip2 air calibration
F4 ESC Back to process variable screen

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PGC Inc. 500-1000 CFM Conditioner Model # 9354-6156-B000 October 2013
10.5 RH Calibration

The RH temperature is provided by the Rotronic HygroClip2. The Smart Pad™ can
calibrate up to 100 RH points in the HygroClip2. However, all calibration points must
be set before an adjustment takes place. Using the ADJUST function adjusts the RH
measurement curve based on existing RH calibration points, but ERASES all
calibration points when the function is complete.
To set an RH calibration point in the HygroClip2, operate the unit until it is stable. Once
stability has been reached, read the value from the reference sensor and enter it into the
Ref. Value field. Press F2 to set a calibration point. No immediate effect will be noticed.
Proceed to the next calibration point and repeat this procedure. Do not adjust the probe
until all of the calibration points have been entered.
When all of the RH calibration points have been entered, press F3 to adjust the calibration.
After several seconds, the RH actual value will change to the value based on the new
calibration.
The RH calibration may be set to the original Rotronic factory calibration values by
pressing F1 for ERASE.

F1 ERASE Restore Rh calibration to factory

calibration default (Rotronic
calibration) values
RH CALIBRATION
F2 CAL Set RH calibration point (up to 100
RH Actual 50.0 %
allowable)
Ref. Value 48.9 %
ERASE CAL ADJUST ESC F3 ADJUST Adjust HygroClip 2 RH calibration
– uses all current calibration points
to create a measurement curve,
then adjusts the calibration and
deletes all calibration points
F4 ESC Back to process variable screen

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PGC Inc. 500-1000 CFM Conditioner Model # 9354-6156-B000 October 2013

10.6 Water Temperature Calibration

The RTD can be calibrated via the user interface. This sensor was calibrated prior to
shipment and typically will not require re-calibration.

The RTD can be calibrated by plugging precision resistors in place of the RTD, or by
comparing the temperature measured by the RTD with a reference standard. In either
method, the RTD can be calibrated using a zero and span adjustment, or it can be
calibrated to a single offset point. If the single offset point adjustment is required, use the
Zero routine.
RTD Calibration Procedure with Reference DIN RTD Ohms to
Temperature Conversion
Standard:
Temperature Resistance
a. Place the reference standard (NIST traceable (C) (Ohms)
thermometer or thermocouple) in close -10 96.15
proximity to the control RTD. -5 98.08
b. Operate the system at the minimum 0 100.00
temperature; or if performing a single point 5 101.93
offset calibration, operate the system at the 10 103.85
desired offset temperature. 15 105.78
c. Access the RTD calibration screens in the 20 107.70
Smart Pad™: 25 109.63
d. Enter the temperature measured by the 30 111.55
reference standard and calibrate the RTD 35 113.48
ZERO value. 40 115.40
e. Operate the system at or near the maximum 45 117.33
temperature and allow adequate time for the 50 119.25
temperature to stabilize. 55 121.18
f. Access the RTD calibration screens in the 60 123.10
Smart Pad™: 65 125.03
g. Enter the temperature measured by the 70 126.95
75 128.88
reference standard and calibrate the RTD
80 130.80
SPAN value.
85 132.73
90 134.65
95 136.58
RTD Calibration Procedure with Precision 100 138.50
Resistors:
a. Place the low temperature precision resistor in the RTD circuit.
b. Access the RTD calibration screens in the Smart Pad™:
c. Enter the temperature represented by the precision resistor value and
calibrate the RTD ZERO value.
d. Place the high temperature precision resistor in the RTD circuit.
e. Enter the temperature represented by the precision resistor value and
calibrate the RTD SPAN value.

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11. Factory Settings

The operational parameters of the PGC conditioner were configured at the factory. This
section tells you the parameters that the PGC conditioner was set to at the factory.

TUNING VALUES
Air Band 10°C
Air Rate 3
Water Band 15°C
Water Rate 3
Rh Band 15%
Rh Rate 0.25
Minimum Water Set Point 02.5°C
Maximum Water Set Point 59°C

CONTROL MODE
Rh Cascade

OVER TEMPERATURE THERMOSTAT SETTING

150°F

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12. Specifications for the PGC Conditioner

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13. Parts List for the PGC Conditioner

DESCRIPTION MANUFACTURER MFG PART # PGC PART #
ACE 9 Board PGC Firmware: 2041 1607-0221B
Air Filter Grainger High Capacity 6B958 1619-0229
Audible Alarm Eaton ECX2070-24 0416-0431C
Circuit Breaker Sprecher & Schuh L9-3/1/D 0430-1030
Circuit Breaker Sprecher & Schuh L9-1.5/1/D 0430-3150
Circuit Breaker Sprecher & Schuh L9-1.5/1/D 0430-1015
Compressor Copeland ZB19KCE-TFD-230 1510-0104
Condenser, Air Cooled Cancoil Condenser Coil 2 Ton 1510-0013
Condensing Unit PGC OEM 1510-000CAN
Condensing Unit, Fan Blade Air Drive 083-0033-01 1602-0283
Condensing Unit, Fan Motor Copeland 950-0265-00 0552-0802
Contactor(s) Sprecher & Schuh CAT7-30E-00-24E 0431-3024D
Damper Assembly PGC OEM 5000-1391
Evaporator Coil Super Radiator Coils 16.5X32(3R) 58/144 1244-0066
Filter EMI Corcom 2EB3 1619-1053
Filter, Water, Particulate McMaster 9316tT22 0215-1800
Fuse, Power Supply Bussman GDB-4A 0407-0970
Gasket, Inner Door PGC OEM 1604-0153
Gasket, Spray Chamber Access PGC OEM 1604-0101
Heater, Air Vulcan Electric Co. D46/5200/12-4 0416-0509
Heater, Water Vulcan Electric Co. L04/002/015001 0416-0604
HygroClip2 RS-485 Cable Rotronic E2-05XX-MOD 1610-0170
HygroClip2s Exchange Sensor, Full Range
PGC OEM 8001-0200
Calibration
HygroClip2s Not Calibrated Rotronic HC2-S 1610-0865
HygroClip2s With Full Range Calibration PGC OEM 1610-0865B
Latch PGC OEM 1001-0083
Motor Starter(s) C3 Controls 330-T25S2D16 0427-0160
Motor, Cooling Fan Orion OD6025-24HB 1602-0269
Motor, Damper Actuator Belimo LMX24-MFT 1608-1916
Motor, Process Blower Rosenberg N63-28043 1602-0190
Phase Sensing Relay Macromatic PMDU 0416-1257B
Power Supply, 24VDC, 45Watt Meanwell PS45-24 1607-0024
Pump March MFG. TE5.5CMD 1/5 HP 1619-0121
Refrigerant Baker R404A 0100-0404
Refrigeration Filter/Dryer Sporlan C-164-S-T-HH 0215-0889
Refrigeration Receiver Copeland 577-0315-05 1510-0320
Refrigeration Sight Glass Sporlan 700130-072 1603-0150
Relay, Water Heat Carlo Gavazzi RGC1A60D20KGU 0416-0384-20DC

Relay, Air Heat Carlo Gavazzi RGC1A60D20KGU 0416-0384-20DC

RTD, Water Temperature Sensor JMS Southeast DWG12699 1619-0862
Serial Cable Cable Wholesale 10D1-03406 0420-0521
Smart Pad PGC Firmware: 2031 1607-1100D
Spray Eliminator PGC OEM 5000-0135
Spray Nozzles Spraying Systems 16-5018-0504 1612-0201
Switch, Low Water FPI Sensors 04210060 0421-0060
Switch, Pressure Control Copeland 085-CP2M-7K 0423-0683

Parameter Generation and Control, Inc. 36

 PGC Inc. 500-1000 CFM Conditioner Model # 9354-6156-B000 October 2013
Thermostat , Air Over Temperature,
Thermtrol TS-120S-S 1636-0223
Adjustable
Thermostat, Air Over Temperature, Fixed PGC OEM 1636-0223-105C
UV, Ballast Robertson PSK2GPH18MV 1619-0150-DV
UV, Bulb Severn Trent Water 8100UD 0215-2835
UV, Hour Meter Eaton Cutler Hammer E42DIR48230R 0215-2821
UV, Power Supply PGC OEM 0215-2834C
UV, Quartz Tube Severn Trent Water 2450UD 0215-2824
Valve, Expansion Sporlan SSE-2-CP115 0215-0845
Valve, Float Control Devices RM262 0209-0054B
Valve, Hot Gas Bypass Sporlan SDR3-1/2x ½-20-S 0215-0873
Vibration Isolator Grainger 4C989A 1611-0500
Zinc Anode PGC OEM 0200-0802A

Parameter Generation and Control, Inc. 37

PGC Inc. 500-1000 CFM Conditioner Model # 9354-6156-B000 October 2013

14. Warranty
PARAMETER GENERATION AND CONTROL, INC., PRODUCTS: The Seller
warrants only that all apparatus manufactured or repaired by us, excluding items which
are products of other manufacturers included as component parts of Parameter
Generation & Control, Inc., manufactured products, are free from defects in material and
workmanship which might impair its usefulness; Seller does not warrant that the
equipment and/or apparatus is fit for any particular use; our obligation under this
warranty is limited to repairing or replacing, at our factory, any defective parts, when
returned to us by our customer, transportation charges prepaid, and which our
examination discloses to have been factory defective. The time limit of this warranty is
one year from date of shipment of a new apparatus and three months from date of
shipment of repaired apparatus. THIS WARRANTY IN LIEU OF ALL OTHER
WARRANTIES EXPRESSED OR IMPLIED and no other affirmation of the Seller, by
words or action shall constitute a warranty, and all other obligations on our part either to
the original purchaser or to any other person provided further, Seller shall not be held
liable for any special, indirect or consequential damages arising out of this warranty or
any breach thereof, or any defect in or failure or malfunction of the equipment and/or
apparatus furnished hereunder. Subject to compliance with the foregoing requirements of
this paragraph, all equipment and materials may be subject to tolerances and variations as
are consistent with usage of the trade. If the services of PGC personnel are required to
supervise or check the installation of "UNDER WARRANTY" equipment, to start up,
make adjustments, inspect or repair such equipment in the field, there will be a charge per
eight-hour day or less, plus travel time and travel and living expenses. Charges for
overtime or work on Saturdays, Sundays, and Holidays are extra. OTHER PRODUCTS:
We make no express or implied warranty as to other items, which are the products of
reputable manufacturers, sold under their respective brands or trade names or included as
component parts of Parameter Generation & Control, Inc., manufactured products. We
shall use our best efforts to obtain from the manufacturer in accordance with its
customary practice, the repair or replacement of such of its products as may prove
defective in workmanship or material. The foregoing states our entire liability in respect
to such products, except as an authorized executive of the Corporation may otherwise
agree in writing.

Parameter Generation and Control, Inc. 38

 APPROVAL DRAWING
Parameter Generation
INITIAL: DATE: & Control, Inc.
Black Mountain, NC A 9354-6156-B000 1
 APPROVAL DRAWING
Parameter Generation
INITIAL: DATE: & Control, Inc.
Black Mountain, NC A 9354-6156-B000 2
 APPROVAL DRAWING
Parameter Generation
INITIAL: DATE: & Control, Inc.
Black Mountain, NC A 9354-6156-B000 3
 APPROVAL DRAWING
Parameter Generation
INITIAL: DATE: & Control, Inc.
Black Mountain, NC A 9354-6156-B000 4
 APPROVAL DRAWING
Parameter Generation
INITIAL: DATE: & Control, Inc.
Black Mountain, NC A 9354-6156-B000 5
 APPROVAL DRAWING RICK SPERRY
Parameter Generation
INITIAL: DATE: & Control, Inc.
Black Mountain, NC A 9354-6156-B000 6
Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

Smart Pad¥ Operation Manual

Revision F: June 2012

www.humiditycontrol.com ~ (828) 669-8717

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Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

Table of Contents

Introduction .................................................................................................................... 3
Set point Entry Modes ..................................................................................................... 3
Control Modes ................................................................................................................. 3
Interface ........................................................................................................................... 4
Low Temperature Mode .................................................................................................. 5
Serial Communication ..................................................................................................... 5
Steady State Mode ....................................................................................................... 6
Process Variable Screen (Steady State Mode) ................................................................. 6
Process Set Point Screen ................................................................................................. 7
Monitor Water/Auxiliary RTD Parameters Screens ........................................................ 7
Output Screen .................................................................................................................. 8
Alarm Condition Screen .................................................................................................. 9
Information Screen ........................................................................................................ 10
Programmable Mode .................................................................................................. 10
Program Functionality ................................................................................................... 10
Process Variable Screen ................................................................................................ 11
Set Point View Screen ................................................................................................... 12
Program Menu ............................................................................................................... 13
Program Segment Screen............................................................................................... 13
Program-Change Byte.................................................................................................... 13
Loop Screen ................................................................................................................... 15
Programming Example .................................................................................................. 15
System Configuration .................................................................................................... 16
Control Menu................................................................................................................. 17
Alarm Menu................................................................................................................... 17
Setup Menu .................................................................................................................... 18
Calibration Menu ........................................................................................................... 21
Air Calibration (When Utilizing HygroClip 2) ............................................................. 22
Air RTD Calibration ...................................................................................................... 22
RH Calibration (When Applicable) ............................................................................... 23
Water RTD Calibration (When Applicable) .................................................................. 24
Auxiliary RTD Calibration ............................................................................................ 24
Serial Communications .............................................................................................. 25
Overview ....................................................................................................................... 25
PGC SmartLog .............................................................................................................. 25
Hardware Connections .................................................................................................. 26
Terminal Protocol .......................................................................................................... 26
Types Of Commands ..................................................................................................... 26
Request commands ........................................................................................................ 28
Input Commands............................................................................................................ 29
Screen Flow Charts .................................................................................................... 30

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Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

Introduction

The PGC control system consists of the ACE control module and the Smart Pad™ user interface.
The ACE control module is responsible for all PID control and for directly interfacing with
sensor inputs and control outputs, whereas the Smart Pad™ communicates the set points to the
ACE controller and receives and displays the current system data provided by the ACE
controller. This manual will discuss the operation of the Smart Pad™ user interface.

Set point Entry Modes

To control the air temperature, relative humidity, or water set points, the Smart Pad™ may be
configured in one of two set point entry modes: steady state mode and programmable mode.
In steady state mode, set points are accessed manually by the user and do not change until the
user enters new set points. In programmable mode, a set point profile is created. The profile,
which consists of up to 50 profile segments, each lasting up to 100 hours, is then used to
automatically adjust the control set points.

Control Modes
The Smart Pad™ is capable of operating in several control modes; two temperature, RH cascade,
dryer, slow damper, and temperature only. In addition, a low temperature mode is used to
prevent the freezing of water in the system. Not all modes are accessible in every system.

RH cascade mode set points control air temperature and relative humidity. The relative
humidity is controlled to the set point by changing the temperature of the water spray, saturating
the air passing through the spray chamber, and then reheating the air to achieve the desired dew
point. Therefore, the water temperature is controlled automatically in RH cascade mode based
on the current RH measurement and the RH set point.

In two-temperature mode, the set points control air and water temperature directly. The
desired RH must be determined either by measuring the conditions in the chamber, or by using a
standard air/RH/water spray graph.

Dryer mode is applicable only for units equipped with a desiccant dryer. In this mode, the air
temperature and RH set points are entered by the user and the RH is controlled using a desiccant
dryer.

Slow damper mode controls the RH in the same way as RH cascade mode. However, in slow
damper mode, the user chooses how much air heat should be added to the system when the unit is
controlling the air temperature at the set point. In this case, much of the air temperature control
is provided by movement of the damper, which heats or cools the air by diverting air around or
through the saturator. This mode allows the unit to use less energy in many conditions, and also
enables the unit to control at some extreme conditions that would be impossible with the other
control modes.

Temperature only mode controls only the air temperature.

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Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

Interface
The Smart Pad™ interface consists of a four-line backlit LCD display, a row of four function
keys, a number pad, and an on/off key. The topmost three LCD lines display data, whereas the
bottom line displays links that are controlled by the four function keys. The function keys
perform different tasks depending on the current screen displayed. The bottom line of the
display is used as a screen specific label for the function key that is directly below it. If a key
has no function or if the function is disabled, the title is blanked out. Whenever the character
is encountered, the function key underneath it will scroll to the next menu, and whenever ESC is
chosen, the Smart Pad™ will revert to the main process variable screen.

The on/off function of the system is also configured to match the hardware applied. If the
system is equipped with a physical on/off switch, the on/off function in the Smart Pad™ can be
disabled. When the on/off function in the Smart Pad™ is enabled, the standby key will force
the ACE controller to enable or disable the main contactor or relay, removing power from the
blower, water pump, heaters, and refrigeration. However, the electronics will still be powered
when the system is in standby mode.

The Smart Pad™ does not use an enter key to input values. Instead, a value will be
received when all numbers have been entered. For instance, to change a set point to 25.0, the
user must input 2-5-0. Inputting only two of the numbers will result in the Smart Pad™ not
accepting the value.

Data Display (Top Three Lines)

Function Key Title Line (Bottom line)

Function Keys

Number Pad

Standby Key

Smart Pad¥ Control Interface

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Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

Low Temperature Mode

For conditions where freezing of the system water is possible, the water is automatically
drained from the system and low temperature mode is activated. This automated
process is only available on units that are equipped to run at very low temperatures, or
that have special conditions that require low temperature mode. When the unit runs in
low temperature mode, the refrigeration unit controls the air temperature directly instead
of the water spray. When using dryer mode, low temperature mode is automatically
enabled, since the system will be running with no water.

The actual trigger for entering low temperature mode is the condition where the air set
point or the air temperature have dropped below the low temperature switch point (see
Setup Menu) by an amount greater than the low temperature dead band. Conversely,
the system will not be in low temperature mode after the air set point or air temperature
have passed above the low temperature switch point by an amount greater than the low
temperature dead band.

When in low temperature mode, the process variable screen will prominently display an
asterisk ( ) beside the air temperature.

Low Temperature Mode Indicator

Serial Communication
The Smart Pad™ is equipped with a serial port that may be used to communicate system
information. This serial port may be accessed via a DB-9 male connector on the cabinet.

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Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

Steady State Mode

Process Variable Screen (Steady State Mode)

The process variable screen displays the measured process variables. Pressing the ESC function
key on other screens will access the process variable screen. The word Actual denotes the
current measured condition in the chamber.

RH Cascade/Dryer/ Two Temperature Temperature Only

Slow Damper

F1 = No function

F2 = Set point screen

F3 = Output screen
F4 = More menu options

Pressing F4 on the process variable screen will access more menu options:

F1 = Main menu
F2 = Set point screen
F3 = Configuration menus
F4 = Smart Pad™ information
screen

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Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

Process Set Point Screen

The process set point screen displays the current control set points and accepts new set points.
In two temperature mode, the water set point will be visible instead of RH set point, and in
temperature only mode, only the air set point will be visible. This screen allows the user to
view and/or modify the set points for the system. When accessing this screen, note the
following:

x The controller does not have an enter key. The set point will be entered into the
controller when the entire field is filled. When the field is filled the cursor will return
to the beginning of the field to indicate proper data entry.

x If all characters are filled into the set point field and the set point does not change, the
entered value may be out of the accepted range. The set point entry ranges may be
changed in the setup menu, but the ranges are most often set for the range of the unit, or
for the safety of the unit, so changing them is not recommended.

x This screen can be locked. Locking this screen will enable any user to view the set
point but will not allow changes to the set point. If this screen is locked the cursor will
not be visible and the TAB key will have no label or function.

F1 Positions the cursor (when screen

not locked out)
F2 View water control parameters
(Only in rh cascade and slow
damper modes)
F3 View auxiliary RTD control
parameters
F4 Back to process variable screen

Monitor Water/Auxiliary RTD Parameters Screens

The monitor water parameters screen allows the user to observe the measured water temperature
as well as the set point and output that are both determined by the cascade control loop. These
values cannot be modified. This screen is available only in cascade or slow damper cascade
mode.

The auxiliary RTD is the same kind of temperature sensor as the water RTD. It is used most
commonly to control a door or window heater to prevent condensation, but may be used for
custom purposes and sometimes isn’t used at all. However, the auxiliary parameters screen is
always visible in all modes. The auxiliary RTD parameters are displayed the same as the water
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Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

parameters, except there is a separate set point screen. The auxiliary RTD set point screen will
accept a new set point if the auxiliary RTD control is set to manual mode. If the auxiliary RTD
control is set to auto mode, the auxiliary RTD control set point will be controlled automatically
as defined by parameters set by the user (see Setup menu).

F1 No function
F2 No function
F3 x Water values screen – No function
x Auxiliary values screen – navigate
to the auxiliary set point control
screen.
F4 Back to process variable screen

The auxiliary set point control screen has two possible states. When auxiliary set point control is set to
manual, a set point may be entered on this screen, otherwise, auto is displayed and no input may be
accepted.

Output Screen

The output screen indicates the position of the air bypass damper, dryer bypass damper and the
power applied to the air and water heaters. These outputs can be in the range of 0.00% (full
cooling) to 100.0% (full heating). This screen is view only.

F1 No function
F2 No function
F3 No function
F4 Back to process variable screen

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Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

Air Heat Out - indicates the percentage of full output being delivered to the heaters in the air
stream. This will also indicate the position of the air bypass damper actuator in the two
temperature and cascade control modes. This output is present all modes.
x When the system operates in low temperature mode the output percentage of the air
heaters may be limited in firmware. A typical limit would be 25%. This means that if
the air heater control is calling for full output in low temperature mode, the Air Heat Out
display will show 25% and the actual heater will only receive 25% of the maximum
output available.
x When the system is operating in normal (not low temperature mode) the air heat out will
reflect the actual heater duty cycle.

H2O Heat Out - indicates the duty cycle of the resistance heaters in the water control system
(water heaters are not standard on all units). This will also represent the output percentage
being delivered to the refrigeration control. This output is not present in dryer mode, low
temperature mode, or temperature only mode.

Refrig. Out - indicates the position of the hot gas bypass control actuator in the refrigeration
system. This output is only present in low temperature and temperature only modes, and when
those modes are active, the refrigeration output shows the output controlling the air temperature
instead of the water spray.

Air Damp Out - indicates the position of the bypass damper. This output is present only in
slow damper cascade mode.

Dryer Out - indicates the position of the desiccant dryer control dampers. This output is
present only in dryer mode.

Alarm Condition Screen

The alarm condition screen indicates the status of all alarms in the system. Though alarms may
be acknowledged or reset from this screen, alarm setup can only be changed by accessing the
alarm menu in the system configuration section. To learn more about the functionality of the
alarm system, see Alarm Menu.

F1 No function
F2 No function
F3 No function
F4 Back to process variable screen

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Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

Line two will display the current alarm state, and will read No Alarm if there is no alarm
condition. If multiple alarms occur only the first alarm will be displayed. However, the labels
of the process variables that are alarming will blink on the process variable screens.

Line three indicates the alarm delay. This is a user defined delay timer for the alarm. An
alarm condition will not trigger an alarm until the alarm delay timer has expired. Line two will
display the alarm as soon as it occurs and line three will begin to decrement the timer. If the
alarm condition is corrected before the alarm delay timer expires no alarm will occur. If the
alarm delay timer expires, the alarm output will be set and the process variable labels will blink.

To pause the alarm condition timer and prevent the alarm output from being set, ACK may be
pressed, which will acknowledge the alarm condition. This will cause line two to display
ALARM ACKNOWLEDGED. This is not the same as resetting the alarm, as once the alarm is
set, ACK will not reset the alarm output. The purpose of the acknowledge option is to give the
ability to correct the impending alarm condition before the alarm is set.

RESET will reset the alarm timer and reset the alarm condition. The display will cease to flash
and the open collector output will open. Any new alarm will trigger the alarm delay timer and
will be recognized if the timer expires.

Information Screen

The information screen displays the unit serial number, Smart Pad™ firmware version
number, as well as the current control mode.

F1 No function
F2 No function
F3 No function
F4 Back to process variable screen

Programmable Mode

Program Functionality

In programmable mode, a profile, or program, may be created to automatically control set

points. Each segment of the profile is programmed with set points which will be
assigned to only that segment (e.g. air and RH), a segment time, which controls the
duration of the segment, and a program change byte, which controls special outputs and
automatic mode changes.

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Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

The program is designed to change the set point from its current value to the desired
value of the current segment by the end of the duration of the segment. Typically, a
program will consist of a sequence of ramps and dwells. A ramp would define the time
required for the set points to change from one condition to another. A dwell would
define the amount of time that the set points will remain stable at the new set point. In
this fashion, it will usually require two segments (one ramp and one dwell) for each
condition that is to be achieved.

The program is also equipped with loop parameters: Start at seg, Loop from seg, and
Loop to seg. The program will begin at the Start at seg segment. It will increment the
segment counter until it has finished the Loop from seg segment. Once that segment is
complete, it will jump to the Loop to seg segment. If the Loop to segment is greater than
the Loop from segment, the program will skip the segments in between, and run through
all remaining segments, looping back to segment 00 after then end segment is finished.
The cycle will repeat until it is interrupted.

A Smart Pad™ profile consisting of two dwells followed by one ramp – created by programming five
segments. Segments 1 and 3 are required only to move the set point quickly to the dwell condition. No
such transition segment is needed for the ramp condition.

Process Variable Screen

In programmable mode, the process variable screen also includes information about the current
program. SEG indicates the current segment and TIME indicates the time left in the current
segment. If the program is running the time will be decrementing. If the program is halted the
time will be static.

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Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

F1 Start or stop the program.

Function label toggles
between run and halt.
F2 Set point view screen
F3 Output screen
F4 More menu options

Pressing F4 will access more menu options:

F1 Main menu options

F2 Program Segment screen
F3 System configuration
F4 More menu options

Pressing F4 will access more menu options:

F1 Previous menu options

F2 Alarm condition screen
F3 Smart Pad™ information
screen
F4 No function

Set Point View Screen

From this screen, the process variable set points may be monitored, as well as the status
of the program change byte and RTD control parameters

F1 View water control parameters (see

Monitor Water/Auxiliary RTD
Parameters Screens)
F2 View auxiliary control parameters
(see Monitor Water/Auxiliary RTD
Parameters Screens)
F3 View program change status
F4 Back to process variable screen
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Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

Program Menu

From this screen, the functions required to create a program may be accessed.

F1 Program segment screen

F2 Set up loop conditions
F3 Initialize program at start segment
F4 Back to process variable screen

Program Segment Screen

From this screen, the profile parameters may be programmed into the Smart Pad™.
SEG indicates the segment number to be programmed, and TIME indicates the duration of
the segment being programmed. The entered set points for each segment will be
reached by the end of the segment. The Smart Pad™ is only controlling the amount
of time required for the set points to change. The actual time required for the
conditions in the chamber to change will depend on many physical factors,
including model, tuning values, and ambient conditions.

See the programming example at the end of the end of this section for more details on
programming segments.

F1 Tabs between segment, set points,

and time fields
F2 View previous segment parameters
F3 View next segment parameters
F4 Show program change byte for
selected segment – Escape from
program change byte screen

Program-Change Byte

The program-change byte screen allows the program to automatically change operating modes
and control special outputs on select units.

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Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

Seg: indicates the selected segment to be programmed and may be changed by typing the
desired segment into the Seg field or by scrolling in the Program Segment screen. The
two digit number after the Program Change: label represents the program byte for the
selected segment. Time indicates the duration of the segment being programmed.

F1 Back to program set point screen

F2 Tabs between segment and
program-change byte
F3 No function
F4 Back to process variable screen

The data is arranged in two characters that represent a single byte (or two nibbles). Each nibble
can be represented by a hexadecimal number from 0 to 9 (hex A through F are not used).

The high nibble (left digit) consists of four digital switches. Each switch is closed or on when
the bit is high, and off when the bit is low.

The low nibble (right digit) is used to configure the operating mode of the chamber. Bit 2 is
used as a reconfigure indicator. If this bit is set, the system will reconfigure the operating mode.
If this bit is clear, the system will ignore the mode indicator. Bits 0 and 1 represent the mode
indicator.

Left Digit Definition (Select Units Only) Right Digit Definition

Data Output 1 Output 2 Output 3 Data Mode Reconfigure

0X OFF OFF OFF X0 no action

1X ON OFF OFF X1 no action

2X OFF ON OFF X2 no action

3X ON ON OFF X3 no action

4X OFF OFF ON X4 CASCADE MODE

5X ON OFF ON X5 TWO TEMPERATURE MODE

6X OFF ON ON X6 DRYER MODE

7X ON ON ON X7 SLOW DAMPER MODE

8X OFF OFF OFF X8 TEMPERATURE ONLY MODE

9X ON OFF OFF X9 no action

Definition of the two-digit program-change byte.

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Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

Programming examples:

PRGC = 00 – All digital outputs are off. System will not reconfigure.
PRGC = 70 – Digital outputs 1, 2, and 3 are on. System will not reconfigure.
PRGC = 16 – Digital output #1 is on. System will reconfigure to mode 02 (Dry mode)

Loop Screen

The loop screen allows the user to specify the loop parameters for the profile. Start at seg
indicates the initial segment in the profile. Loop from seg indicates the final segment in the
profile. Loop to seg indicates the segment the controller will execute immediately following the
final segment.

F1 Tabs between loop parameters

F2 Nofunction
F3 No function
F4 Back to process variable screen

Examples:
x If Start At Seg = 00, Loop From Seg = 05, Loop To Seg = 02. The controller will execute segments 00
through 05 in sequence then loop from 05 to 02. The controller will then continue to execute segments 02
through 05 indefinitely until the profile is halted or altered.

x If Start At Seg = 00, Loop From Seg = 05, Loop To Seg = 05. The controller will execute segments 00
through 05 in sequence. Then, since the loop to segment is the same as the loop from segment, the
controller will loop from 05 to 05. The controller will then continue to execute segment 05 indefinitely
until the profile is halted or altered.

Programming Example
Create a program that runs the air handler set points at 25°C/50%RH for five hours, then at 40°C/75%RH for five
hours, then slowly ramps the set points back down to 25°C/50%RH over the course of five more hours, and then
repeats.
1. To achieve this program, we will need to first ramp the set points to 25°C/50%RH in segment zero.
Navigate to the Program Segment screen. Use the Prev and Next functions, or type 00 into the Seg field to
select segment 00.
2. Using the tab key, choose the time field for segment 00. The time field displays hours, minutes, and
seconds in the format 00:00:00. Choose a small amount of time to ramp the set points, such as 5 seconds.
The segment time must be greater than 0. Type 0-0-0-0-0-5 (00:00:05) to choose five seconds for this
segment.
3. Using the tab key again, choose air set point and type 2-5-0 to choose 25.0°C. Tab to the RH field and
type 5-0-0 to choose 50.0%RH.
4. Use the Next function to choose segment 01. In this segment, now that our set points are at our first
condition, we will dwell the set points at 25°C/50%RH for five hours. Literally speaking, this segment
will “ramp” the set points from 25°C/50%RH to 25°C/50%RH, creating the dwell. Using the tab key
and the keypad again, type 0-5-0-0-0-0 in the time field to choose five hours, and choose 25°C for air set
point and 50% for RH set point. This will maintain the set points at 25°C/50%RH for five hours for the
duration of the first condition.
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Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

5. Use the Next function to choose segment 02. In this segment the set points will ramp quickly from the first
condition to the second condition. Choose five seconds for the time (00:00:05), 40°C for the air set point,
and 75% for the RH set point.
6. Use the Next function to choose segment 03. This segment will comprise our second dwell at
40°C/75%RH. Choose five hours for the time (05:00:00), 40°C for the air set point, and 75% for the RH
set point.
7. Use the Next function to choose segment 04, the last segment of this profile. The set points are at
40°C/75%RH at the start of this segment, and we want to ramp them to 25°C/50%RH by the end of the
segment over five hours, so choose five hours for the time (05:00:00), 25°C for the air set point, and 50%
for the RH set point.
8. Now that the program is complete, we want to repeat the two dwells and one ramp indefinitely. When the
program gets to the end of segment 04, the set points are at the first condition, so the initial set point
ramping segment, segment 00 is not needed. So we will loop from segment 04 to segment 01. In the
loop menu, choose 00 for Start at seg, 04 for Loop from seg, and 01 for Loop to seg.

System Configuration
The system configuration menus may be accessed in any operating mode. To access the
configuration menus, a four-digit access code must be entered into the configuration access
screen. The custom code, “0000” when the unit is shipped, will allow access to the customer
configuration screens. These screens will allow the user to reprogram the access code, address
the alarm parameters, lock the keypad, calibrate sensors, modify the tuning parameters, and
access other settings. All four characters must be entered for the Smart Pad™ to accept the
code.

F1 No function
F2 No function
ႃ
F3 No function
F4 Back to process variable screen
Correct Code Access to configuration menus

Once the correct code has been entered into the access screen, the system configuration menu
will be visible. To toggle between menu items use the function keys marked with arrows ( or
). This screen allows the user to select the user accessible configuration options.

F1 Control/set point entry mode menu

F2 Alarm setup menu
F3 Tune menu
F4 More options

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F1 No function
F2 No function
F3 No function
F4 Back to process variable screen

Control Menu
The desired unit control mode and the set point entry mode are selected in the control
menu. The arrow keys toggle between the set point entry mode choices and the control
mode choices. Change scrolls through the options, and Enter is pressed when a
selection has been made. The user is then prompted with a warning message: “Change
unit control method?” If no is selected, the current mode of operation does not change.
If yes is selected the Smart Pad™ will reboot in the selected modes.

F1 Next control menu

F2 Next control menu
F3 Select next control method
F4 Choose selected control mode and
set point entry mode

Control Menu
Control Mode Rh Cascade
Two Temperature
Dryer
Slow Damper
Temperature Only
Set Point Entry Mode Steady State
Programmable

Alarm Menu

The Smart Pad™ has three alarm channels, for air temperature, RH, and water temperature, and
each alarm can be set to be tripped by limits or deviation. Each channel may be configured
separately to be tripped by either limits or deviation. Not all units utilize all three alarm
channels.
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When an alarm is set to trip by limits, a high and low limit are chosen. When alarms are
enabled and a process variable strays above its high alarm limit or below its low alarm limit, the
user-set alarm timer will begin to count down. The alarm output will not be set until the timer
countdown is complete. This is to prevent a momentary overshoot from tripping an alarm.

When an alarm is set to trip by deviation, the alarm limits are relative to the set point. The
process variable is in alarm condition when it passes beyond the set point plus or minus the
deviation value. For example, if the air set point is 25.0°C, and the deviation is 10.0°C, the air
temperature will be in alarm condition if it reaches 35.1°C or 14.9°C. Deviation is useful when
the set points must be ramped to different conditions in programmable mode; it allows for tighter
limits than when using the limits feature.

Submenu Parameter Value

General Alarm Alarms
Config Disabled
Alarms
Enabled
Timer 00:00:20
Air Alarm Trip by: Limits
Config Deviation
High Limit 85.0
Lo Limit 03.0
F1 Next submenu Deviation 20.0

Next submenu RH Alarm Trip by: Limits

F2
Config Deviation
F3 Select next control High Limit 85.0
method
Lo Limit 03.0
F4 Choose selected Deviation 20.0
control mode and
set point entry Water Alarm Trip by: Limits
mode Config Deviation
High Limit 85.0
Lo Limit 03.0
Alarm Menu 20.0
Deviation

Setup Menu
The setup menu controls many of the advanced settings in the Smart Pad, most of which
will only need to be set during the initial configuration of the system. In order to access
this menu, the advanced access code is needed. This is one of two access codes that
protect the Smart Pad’s menus from inadvertent corruption. This code ships as 5555,
but can be changed in the setup menu.

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F1 Next control menu

F2 Next control menu
F3 Select next control method
F4 Choose selected control mode and
set point entry mode

The following is a listing of the submenus and functions of the setup menu:

Submenu Parameter Value Description

Security Access Code 0000 Change the code that gains entry to the configuration menus
Advanced Code 5555 Change the code that gains entry to the advanced configuration
menus
SP lock: unlocked Lock set points. When locked is displayed in this field, the set
locked points may not be changed via the Smart Pad key pad.
Standby enable: on Enable or disable standby mode. When off is displayed in this
off field, the unit may not be turned off by pressing the standby key.
Set Point Control Air sp hlim 87.5 Limit air set point entry. The air set point can not exceed this
value.
Air sp llim -12.5 Limit air set point entry. The air set point can not be lower than
this value.
RH sp hlim 99.9 Limit RH set point entry. The RH set point can not exceed this
value.
RH sp llim 00.0 Limit RH set point entry. The RH set point can not be lower than
this value.
Wat sp hlim 87.5 Limit water set point entry. The water set point can not exceed this
value.
Wat sp llim -12.5 Limit air set point entry. The air set point can not be lower than
this value.
A/Wsp min dif 01.0 Limit the cascaded water set point with respect to the air set point.
The cascaded water set point will be limited to the air set point
minus this value.
Fast wsp: on Enable or disable fast water set point. Fast water set point allows
off for maximum water temperature transition when the RH is out of its
control band.
Aux SP Control Aux sp ctrl: auto Auxiliary set point control. Control how auxiliary RTD set point is
manual controlled. When auto is displayed, the auxiliary set point is
determined from the values in LT Aux sp and ST wsp offset. When
manual is displayed, the auxiliary RTD control set point is entered in
the Auxiliary RTD Set Point screen.
LT Aux sp 05.0 Low temperature auxiliary set point. When auxiliary set point
control is set to auto and the unit is running in low temperature
mode, the auxiliary set point will be equal to this value.
ST wsp offset 01.0 Standard temperature water set point-auxiliary set point offset.
When the auxiliary set point control is set to manual and the unit is
not running in low temperature mode, the auxiliary set point will
equal the water set point plus this value.
Low Temperature LT switch pt 03.0 Low temperature mode switch point. If the air temperature or the
Mode air set point dip below this value minus the dead band (ltsp-ltdb),
the unit will operate in low temperature mode.
LT dead band 00.2 Low temperature mode dead band. Control how much the air
temperature or air set point must be past the low temperature mode
switch point to change into or out of low temperature mode. This
is used to prevent cycling temperature modes when the air
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temperature or air set point is close to the low temperature mode

switch point.
Coil protect: on Enable or disable coil protection. When on is displayed in this
off field and the unit is running in low temperature mode, the coil is
prevented from dipping below a set point.
DAC Scaling Ch1A out: 050.0% Select whether digital-to-analog converter outputs are forced to set
air temp values or scaled based on temperature or RH.
RH 050.0% – DAC channel 1A (0-10V) set to forced output percentage.
wat temp air temp – DAC channel 1A output controlled by air temperature.
RH – DAC channel 1A output controlled by measured RH.
wat temp – channel 1A output controlled by water temperature
Chan 1A High 87.5 High scaling factor for channel 1A digital-to-analog converter
output. If the controlling process value equals this value, the
output on channel 1A will be maximum (10V).
Chan 1A Low -12.5 Low scaling factor for channel 1A digital-to-analog converter output.
If the air temperature equals this value, the output on channel 1A
will be minimum (0V).
Ch1B out: 050.0% Select whether digital-to-analog converter outputs are forced to set
air temp values or scaled based on temperature or RH. (0-10V)
RH
wat temp
Chan 1B High 99.9 High scaling factor for channel 1B digital-to-analog converter
output. If the controlling process value equals this value, the
output on channel 1A will be maximum (10V).
Chan 1B Low 00.0 Low scaling factor for channel 1B digital-to-analog converter output.
If the air temperature equals this value, the output on channel A will
be minimum (0V).
Ch2A out: 050.0% Select whether digital-to-analog converter outputs are forced to set
air temp values or scaled based on temperature or RH.
RH 050.0% – DAC channel 2A (4-20mA) set to forced output percentage.
wat temp air temp – DAC channel 2A output controlled by air temperature.
RH – DAC channel 2A output controlled by measured RH.
wat temp – channel 2A output controlled by water temperature
Chan 2A High 87.5 High scaling factor for channel 2A digital-to-analog converter
output.
Chan 2A Low -12.5 Low scaling factor for channel 2A digital-to-analog converter output.
Ch2B out: 050.0% Select whether digital-to-analog converter outputs are forced to set
air temp values or scaled based on temperature or RH. (4-20mA)
RH
wat temp
Chan 2B High 99.9 High scaling factor for channel 2B digital-to-analog converter
output.
Chan 2B Low 99.9 Low scaling factor for channel 2B digital-to-analog converter output.

More Settings Auto mode off Enable or disable auto mode change. When on is displayed in this
chng: on field the unit will automatically switch to dryer mode when in low
temperature mode, and will switch to RH cascade mode when not in
low temperature mode.
Alrm as fault: off Enable or disable the alarms-as-faults option. When on is
on displayed in this field, temperature/RH alarms will act as unit faults,
forcing the alarm output and forcing the unit into standby mode in
the event of an alarm.
HC2 fault: off Enable or disable a fault occurrence when no communication is
on detected with the Rotronic HygroClip 2 temperature/RH sensor.
Temp offset -12.5 Temperature offset. This is an offset that is added to temperatures
in the ACE controller firmware and subtracted in the Smart Pad
firmware to ensure that all calculations are performed on positive
numbers. This value will only be changed if the temperature range
of the unit is changed.

DAC Scaling: The DAC Scaling can be used to control functions such as Fan Speed in certain
units.

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Calibration Menu
The calibration menu is also protected by the advanced access code. The user is strongly
encouraged to carefully read the procedures for calibration before attempting to use any
feature in this menu.

There are four possible calibrations that may be performed from the Smart Pad™: air
temperature, relative humidity, water temperature, and auxiliary temperature. The air and RH
calibrations are performed by means of direct communication with the calibration parameters
stored inside the Rotronic HygroClip 2 sensor. The Smart Pad™ cannot calibrate any other
air/RH sensor directly. The Smart Pad™ is capable of a single point air calibration and up
to 100 RH calibration points. In addition, both air and RH calibrations may be restored to
default factory calibration values.

The water and auxiliary RTD calibrations are performed by communicating directly with the
ACE controller board, and the calibration values are stored in the ACE firmware. Two point
calibrations may be performed, and the calibrations may be restored to default values from the
keypad.

In all four calibrations, the current process variable value is shown, as well as a reference value.
The reference value is entered manually by the user and will be obtained from reference sensor,
which must be placed close to the sensor that is being calibrated. When calibrating a sensor,
unit conditions must be at a very stable control point. If the unit shows any trace of
transition, the calibration will not be accurate. When adjusting any of the sensors, the user will
be prompted to continue or abort, in an effort to prevent inadvertent corruption of the calibration.

F1 Air calibration screen

F2 RH calibration screen
F3 Water/Auxiliary RTD menu
F4 Back to process variable screen

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Air Calibration (When Utilizing HygroClip 2)

The air temperature is provided by the Rotronic HygroClip 2. Though the HygroClip 2 allows
for multiple point air calibration using one of its calibration interfaces, such as the HF2, only a
single point calibration may be performed from the Smart Pad™.

To adjust the temperature reading in the HygroClip 2, operate the unit until it is stable. Once
stability has been reached, read the value from the reference sensor and enter it into the Ref.
Value field. Press F3 to adjust the reading. A warning message will prompt the user to
continue or abort. When OK is pressed, the calibration will be sent to the HygroClip 2. In
several seconds, the Air Actual value should change to equal the reference value.

F1 Restore air calibration to factory

calibration default (Rotronic
calibration) values
F2 No function
F3 Adjust HygroClip 2 air calibration
F4 Back to process variable screen

Air RTD Calibration

The air RTD calibration consists of a low point (ZERO) and a high point (SPAN). Subsequent
measurements are calculated with linear respect to these two points. Air calibration points
will be rejected if they are within 10°C of one another. Rejection of a calibration point will
result in the measured process variable not changing.

The reference value for the air RTD calibration may be obtained in one of two ways. The most
accurate method involves placing a reference sensor in the water bath before running the unit at
the desired conditions. A faster, but slightly less accurate method is to replace the RTD with an
accurate variable resistor and calculate the reference value from the known resistance, based on
the PT100 platinum RTD temperature to resistance scale (100Ω = 0.0°C). In this case, the
resistor leads will replace the white wire and one of the red wires on the RTD connector that
plugs into the ACE board.

To set a water calibration point, run the unit in two temperature mode, so the water set point may
be controlled directly. Run the unit until it is stable. Once stability has been reached, read the
value from the reference sensor and type it into the Ref. Value field. Press F2 to set a low, or
zero, calibration point, and F3 to set a high, or span, calibration point.

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RTD calibrations may be reset to factory (uncalibrated) value by pressing F1 for ERASE.

RH Calibration (When Applicable)

The RH temperature is provided by the Rotronic HygroClip 2. The Smart Pad™ can calibrate
up to 100 RH points in the HygroClip 2. However, all calibration points must be set before
an adjustment takes place. Using the ADJUST function adjusts the RH measurement
curve based on existing RH calibration points, but ERASES all calibration points when the
function is complete.

To set an RH calibration point in the HygroClip 2, operate the unit until it is stable. Once
stability has been reached, read the value from the reference sensor and enter it into the Ref.
Value field. Press F2 to set a calibration point. No immediate effect will be noticed.
Proceed to the next calibration point and repeat this procedure. Do not adjust the probe until
all of the calibration points have been entered.

When all of the RH calibration points have been entered, press F3 to adjust the calibration.
After several seconds, the RH actual value will change to the value based on the new calibration.

The RH calibration may be set to the original Rotronic factory calibration values by pressing F1
for ERASE.

F1 Restore air calibration to factory

calibration default (Rotronic
calibration) values
F2 Set RH calibration point (up to 100
allowable)
F3 Adjust HygroClip 2 RH calibration –
uses all current calibration points to
create a measurement curve, then
adjusts the calibration and deletes
all calibration points
F4 Back to process variable screen

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Water RTD Calibration (When Applicable)

The water RTD calibration consists of a low point (ZERO) and a high point (SPAN).
Subsequent measurements are calculated with linear respect to these two points. Water
calibration points will be rejected if they are within 10°C of one another. Rejection of a
calibration point will result in the measured process variable not changing.

The reference value for the water RTD calibration may be obtained in one of two ways. The
most accurate method involves placing a reference sensor in the water bath before running the
unit at the desired conditions. A faster, but slightly less accurate method is to replace the RTD
with an accurate variable resistor and calculate the reference value from the known resistance,
based on the PT100 platinum RTD temperature to resistance scale (100Ω = 0.0°C). In this case,
the resistor leads will replace the white wire and one of the red wires on the RTD connector that
plugs into the ACE board.

To set a water calibration point, run the unit in two temperature mode, so the water set point may
be controlled directly. Run the unit until it is stable. Once stability has been reached, read the
value from the reference sensor and type it into the Ref. Value field. Press F2 to set a low, or
zero, calibration point, and F3 to set a high, or span, calibration point.

RTD calibrations may be reset to factory (uncalibrated) value by pressing F1 for ERASE.

F1 Restore air calibration to factory

default (uncalibrated) values
F2 Adjust low calibration point
F3 Adjust high calibration point
F4 Back to process variable screen

Auxiliary RTD Calibration

The auxiliary RTD is only available on select PGC units. It is used for door heat
control, and less commonly for other custom uses. The calibration of this sensor is
identical to that of the water RTD, except, if using a reference sensor, the sensor will need
to be to be fixed to whatever the auxiliary RTD is measuring. If a reference sensor is
being used, the auxiliary RTD set point control should be set to manual in the Smart
Pad™ setup menu, so the user has direct control over the set points.

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Serial Communications

Overview

The Smart Pad™ is equipped with an RS-232 serial port which may be polled by a remote
terminal application. Through this interface the user can modify or request the value of the
control set points, tuning values, outputs, measured process variables, as well as many
configuration settings. This functionality will allow the user to collect performance data from
the controller or store test procedures on a remote terminal. These stored test procedures can
then be downloaded to the Smart Pad™, giving the user unlimited programming capability.

PGC SmartLog

A complimentary copy of SmartLog is available by request. SmartLog is a Windows-based

platform created by PGC for graphing and logging chamber data, as well as remotely controlling
set points and other configuration utilities. The latest versions of SmartLog are available on the
PGC website at the following link: http://www.humiditycontrol.com/resources

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Hardware Connections

Connect the remote terminal to the nine pin header on the back of the Smart Pad™ or DB-9 Male
connector on the cabinet. Maximum cable length should be limited to 50 feet with RS-232
protocol. The required connections are as follows.
DB-9 Pin # Function
5 Common
2 Terminal Receive (data from Smart Pad™)
3 Terminal Transmit (data to Smart Pad™)

Terminal Protocol

Any terminal program or application that is capable of sending and receiving ASCII characters
should be capable of communicating with the Smart Pad™. All hardware handshaking should
be disabled in the terminal since there are no hardware handshaking connections on the Smart
Pad™ connector. The command sample rate should also be limited to greater than 10 ms
between request commands (?) and 20 mS. between input commands (=).
The protocol settings on the terminal should be:
Baud rate: 9600
Parity: None
Data Bits: 8
Stop Bits: 1
Soft flow control (XON/XOFF): on
Hard flow control (RTS/CTS): off
Carriage return translation: none (CR = CR only)
Line feed translation: strip (CR = CR only)
Line pacing (command frequency): 10 milliseconds or greater for requests, 20 mS or
greater for inputs.
Local character echo: off
Duplex: full
Carrier detection: do not abort if CD is lost (no hardware handshaking)

Types Of Commands

The Smart Pad™ will respond to two types of commands; requests and inputs. A request is a
command that instructs the Smart Pad™ to return a value to the terminal. An example of this is if
the terminal were to request the current measured air temperature. An input is a command that
instructs the Smart Pad™ to accept data, such as changing a set point in the Smart Pad™.

All commands are preceded by either a “?” for a Request or an “=” for an input. This is
followed by a two-character command. Input commands will also include data after the
command. Spaces (SP) are required between the command and the data string. Some
commands require additional formatting punctuation such as commas or colons to differentiate
between data fields. All commands must be followed by a carriage return (CR). The
commands are not case-sensitive. It is important to note that data entered into the Smart Pad™
is stored in non-volatile Flash memory (EEPROM-emulated Flash). This type of memory has a
finite limit to the number of write/erase cycles. The number of writes depends on a number of
factors, but will not exceed several hundred thousand. This should more than exceed the life of
the device for standard keyboard driven data entry. However, if an automatic set point entry

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scheme is used the EEProm could easily be destroyed much faster. Automated and
continuous writing to memory should be avoided.

If a terminal shows unprintable hex characters, formatting and data-handling characters will be
visible when the command responses are received.

All undefined commands or commands with incorrect formatting will yield the response,
“INVALID REQUEST”.

Command Examples:
To request the current air temperature set point:
Command: ?AP[CR]
Response: [13][CR][LF][SP]25.00[CR][LF][11]

To change the current air temperature set point:

Command: =AS 25.00[CR]
Response: [13][CR][LF][SP]25.00[CR][LF][11]

Example of response to a command with incorrect formatting:

Command: =AS25.00[CR]
Response: [13][CR][LF]INVALID REQUEST[CR][LF][11]

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Request commands
Command Function
?OO[CR] Returns current run state (ON or OFF)
?CM[CR] Returns current Control Mode (RC,TT,DY,SD, or TO)
?SM[CR] Returns current Set point entry Mode (SS or PG)
?AP[CR] Returns the current Air Process variable (air temperature)
?AS[CR] Returns the current Air Set point
?AH[CR] Returns Air proportional band
?AR[CR] Returns Air integration constant
?AD[CR] Returns Air Derivative constant
?AO[CR] Returns the Air heater Output percentage
?WP[CR] Returns the current Water Process variable (water temperature)
?WS[CR] Returns the current Water Set point
?WH[CR] Returns Water proportional band
?WR[CR] Returns Water integration constant
?WD[CR] Returns Water Derivative constant
?WO[CR] Returns the Water heat Output percentage
?XP[CR] Returns the current auXiliary RTD Process variable
?XS[CR] Returns the current auXiliary RTD control Set point
?XH[CR] Returns auXiliary RTD control proportional band
?XR[CR] Returns auXiliary RTD control integration constant
?XD[CR] Returns auXiliary RTD control Derivative constant
?XO[CR] Returns the auXiliary RTD control heater Output percentage

The following commands are available in a Cascade mode only.

?WL[CR] Returns cascaded Water set point Low limit
?WU[CR] Returns cascaded Water Upper limit
?RP[CR] Returns the current RH Process variable (measured RH)
?RS[CR] Returns the current RH Set point
?RH[CR] Returns RH proportional band
?RR[CR] Returns RH integration constant

The following commands are available in Dryer mode only.

?RO[CR] Returns RH dryer Output percentage
?RD[CR] Returns RH Derivative constant

The following commands are available in Slow Damper mode only.

?DH[CR] Returns Damper proportional band
?DR[CR] Returns Damper integration constant
?DO[CR] Returns Damper Output percentage
?MA[CR] Returns Manual Adjust

The following commands are available in programmable modes only.

?PR[SP]xx[CR] response: xx,Saa.aa,Sww.ww,hh:mm:ss

Returns the PRogram data for the segment (xx) requested. [S is the
sign if negative, aa.aa is air set point, ww.ww is water or RH set point,
and hh:mm:ss is the time entered in that segment]
?LU[CR] response: ss,ff,tt
Returns the loop parameters. [ss is start segment, ff is loop from
segment, and tt is loop to segment]
?SY[CR] response: [run status] ss,hh:mm:ss, where [run status] is either RUN
or HALT.

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Input Commands
Command Function
=OO[CR] Toggles current run state (On/Off command)
=RC[CR] Instructs Smart Pad to reboot in RH Cascade control mode
=TT[CR] Instructs Smart Pad to reboot in Two Temperature control mode
=DY[CR] Instructs Smart Pad to reboot in Dryer control mode
=SD[CR] Instructs Smart Pad to reboot in Slow Damper control mode
=TO[CR] Instructs Smart Pad to reboot in Temperature Only mode
=SS[CR] Instructs Smart Pad to reboot in Steady State set point entry mode
=PG[CR] Instructs Smart Pad to reboot in Programmable set point entry mode
=AS[SP]xx.xx[CR] Inputs xx.xx as the new Air Set point
=AH[SP]xx.xx[CR] Inputs xx.xx as the new Air proportional band
=AR[SP]xx.xx[CR] Inputs xx.xx as the new Air Reset rate
=AD[SP]xxx[CR] Inputs xxx as the new Air Derivative constant
=XS[SP]xx.xx[CR] Inputs xx.xx as the new auXiliary Set point
=XH[SP]xx.xx[CR] Inputs xx.xx as the new auXiliary proportional band
=XR[SP]xx.xx[CR] Inputs xx.xx as the new auXiliary integration constant
=XD[SP]xxx[CR] Inputs xxx as the new auXiliary Derivative constant

The following commands are available in Two Temperature mode only.

=WS[SP]xx.xx[CR] Inputs xx.xx as the new Water Set point
=WH[SP]xx.xx[CR] Inputs xx.xx as the new Water proportional band
=WR[SP]xx.xx[CR] Inputs xx.xx as the new Water integration constant
=WD[SP]xx.xx[CR] Inputs xx.xx as the new Water Derivative constant

The following commands are available in Cascade mode only.

=WL[SP]xx.xx[CR] Inputs xx.x as the new Water Lower limit
=WU[SP]xx.xx[CR] Inputs xx.x as the new Water Upper limit
=RS[SP]xx.xx[CR] Inputs xx.xx as the new RH Set point
=RH[SP]xx.xx[CR] Inputs xx.xx as the new RH proportional band
=RR[SP]xx.xx[CR] Inputs xx.xx as the new RH integration constant
=RD[SP]xxx[CR] Inputs xxx as the new RH Derivative constant

The following commands are available in Slow Damper mode only.

=DH[SP]xx.xx[CR] Inputs xx.xx as the new Damper proportional band
=DR[SP]xx.xx[CR] Inputs xx.xx as the new Damper integration constant

The following commands are available in programmable modes only.

=GO[CR] Instructs the program to run/resume
=ST[CR] Instructs the program to halt
=LU[SP]ss[SP]ff[SP]tt[CR] response: ss,ff,tt
Inputs xx,yy,zz as the new loop (LUP) parameters [start seg; loop
from seg; loop to seg] This command will also reinitialize the loop
at the new loop parameters.
=PR[SP]xx[SP]aa.a[SP]ww.w[SP]hh:mm:ss[CR]
Inputs the PRogram data, air (aa.a) and water (ww.w) set points and
time (hh:mm:ss), for the segment indicated (xx).
=IN[CR] Instructs the program to INitialize the loop at the existing loop
parameters.
=NS[CR] Instructs program to jump to the Next Segment
=PS[CR] Instructs program to jump to the Previous Segment

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Screen Flow Charts

RH CASCADE MODE
(Steady State)
PROCESS VARIABLE PROCESS VARIABLE 2
Air Actual 24.9°C Air Actual 24.9°C
Rh Actual 50.1 % Rh Actual 50.1 %

SP OUT > < ALM CONFIG INFO

SET POINT OUTPUTS ALARM CONDITION INFORMATION

Air Setpoint 25.0°C Air Heat Out 048.9% ALARM CONDITION PGC Unit SN: xxxxxxx
Rh Setpoint 50.0 % H2O Heat Out 050.1% No Alarm Firmware ver. xxxx
Alarm Delay 00:00:20 Steady State Cascade
TAB WATER AUX ESC ESC ACK RESET ESC ESC

CONFIGURATION ACCESS
WATER PARAMETERS AUX RTD PARAMETERS
Enter access code:
H2O Setpoint 12.7°C Aux Setpoint 13.7°C
H2O Actual 12.8°C Aux Actual 13.7°C █
H2O Heat Out 49.3% Aux Heat Out 046.0% ESC
ESC SP ESC

AUX RTD SET POINT (Auto) AUX RTD SET POINT (Manual)
Aux SP Cntrl: auto Aux Setpoint 23.0°C
Aux SP Cntrl: manual

< ESC ESC

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RH CASCADE MODE
(Programmable)
PROCESS VARIABLE PROCESS VARIABLE 2 PROCESS VARIABLE 2
Air Actual 24.9°C Air Actual 24.9°C Air Actual 24.9°C
Rh Actual 50.1 % Rh Actual 50.1 % Rh Actual 50.1 %
Seg 00 Time 01:00:00 Seg 00 Time 01:00:00 Seg 00 Time 01:00:00
RUN SP OUT > < PROG CONFIG > < ALARM INFO

RUN/STOP

SET POINT OUTPUTS PROGRAM MENU ALARM CONDITION INFORMATION

Air Setpoint 25.0°C Air Heat Out 048.9% PROGRAM MENU ALARM CONDITION PGC Unit SN: xxxxxxx
RH Setpoint 50.0 % H2O Heat Out 050.1% No Alarm Firmware ver. xxxx
Seg 00 Time 01:00:00 Alarm Delay 00:00:20 Steady State Cascade
H20 AUX PRGC ESC ESC SEG LOOP INIT ESC ACK RESET ESC ESC

WATER PARAMETERS AUX RTD PARAMETERS SEG 1 SEG 2 CONFIGURATION ACCESS

H2O Setpoint 12.7°C Aux Setpoint 13.7°C Air Setpoint 25.0°C Program Change: 00 Enter access code:
H2O Actual 12.8°C Aux Actual 13.7°C RH Setpoint 50.0 %
H2O Heat Out 49.3% Aux Heat Out 046.0% Seg 00 Time 01:00:00 Seg 00 Time 01:00:00 █
ESC SP ESC TAB PREV NEXT > < TAB ESC ESC

AUX RTD SET POINT (Auto) AUX RTD SET POINT (Manual) LOOP INITIALIZE PROGRAM
Aux SP Cntrl: auto Aux Setpoint 23.0°C Start at seg 01 Initialize program
Aux SP Cntrl: manual Loop from seg 20 at start segment?
Loop to seg 01
< ESC < ESC TAB ESC OK ABORT

INITIALIZE
PROGRAM

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Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

TWO TEMPERATURE MODE

(Steady State)
PROCESS VARIABLE PROCESS VARIABLE 2
Air Actual 24.9°C Air Actual 24.9°C
H2O Actual 15.1 % H2O Actual 15.1 %

SP OUT > < ALM CONFIG INFO

SET POINT OUTPUTS ALARM CONDITION INFORMATION

Air Setpoint 25.0°C Air Heat Out 048.9% ALARM CONDITION PGC Unit SN: xxxxxxx
H2O Setpoint 15.0 % H2O Heat Out 050.1% No Alarm Firmware ver. xxxx
Alarm Delay 00:00:20 Steady State TwoTemp
TAB AUX ESC ESC ACK RESET ESC ESC

CONFIGURATION ACCESS
AUX RTD PARAMETERS
Enter access code:
Aux Setpoint 13.7°C
Aux Actual 13.7°C █
Aux Heat Out 046.0% ESC
SP ESC

AUX RTD SET POINT (Auto) AUX RTD SET POINT (Manual)
Aux SP Cntrl: auto Aux Setpoint 23.0°C
Aux SP Cntrl: manual

< ESC < ESC

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 Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

TWO TEMPERATURE MODE

(Programmable)

PROCESS VARIABLE PROCESS VARIABLE 2 PROCESS VARIABLE 2

Air Actual 24.9°C Air Actual 24.9°C Air Actual 24.9°C
H2O Actual 15.1 % H2O Actual 15.1 % H2O Actual 15.1 %
Seg 00 Time 01:00:00 Seg 00 Time 01:00:00 Seg 00 Time 01:00:00
RUN SP OUT > < PROG CONFIG > < ALARM INFO

RUN/STOP

SET POINT OUTPUTS PROGRAM MENU ALARM CONDITION INFORMATION

Air Setpoint 25.0°C Air Heat Out 048.9% PROGRAM MENU ALARM CONDITION PGC Unit SN: xxxxxxx
H2O Setpoint 15.0 % H2O Heat Out 050.1% No Alarm Firmware ver. xxxx
Seg 00 Time 01:00:00 Alarm Delay 00:00:20 Steady State Cascade
AUX PRGC ESC ESC SEG LOOP INIT ESC ACK RESET ESC ESC

AUX RTD PARAMETERS SEG 1 SEG 2 CONFIGURATION ACCESS

Aux Setpoint 13.7°C Air Setpoint 25.0°C Program Change: 00 Enter access code:
Aux Actual 13.7°C H2O Setpoint 15.0 %
Aux Heat Out 046.0% Seg 00 Time 01:00:00 Seg 00 Time 01:00:00 █
SP ESC TAB PREV NEXT > < TAB ESC ESC

AUX RTD SET POINT (Auto) AUX RTD SET POINT (Manual) LOOP INITIALIZE PROGRAM
Aux SP Cntrl: auto Aux Setpoint 23.0°C Start at seg 01 Initialize program
Aux SP Cntrl: manual Loop from seg 20 at start segment?
Loop to seg 01
< ESC < ESC TAB ESC OK ABORT

INITIALIZE
PROGRAM

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Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

DRYER MODE
(Steady State)
PROCESS VARIABLE PROCESS VARIABLE 2
Air Actual 24.9°C Air Actual 24.9°C
Rh Actual 15.1 % Rh Actual 15.1 %

SP OUT > < ALM CONFIG INFO

SET POINT OUTPUTS ALARM CONDITION INFORMATION

Air Setpoint 25.0°C Air Heat Out 048.9% ALARM CONDITION PGC Unit SN: xxxxxxx
Rh Setpoint 15.0 % Refrig. Out 050.1% No Alarm Firmware ver. xxxx
Dryer output 000.0% Alarm Delay 00:00:20 Steady State Dryer
TAB AUX ESC ESC ACK RESET ESC ESC

CONFIGURATION ACCESS
AUX RTD PARAMETERS
Enter access code:
Aux Setpoint 13.7°C
Aux Actual 13.7°C █
Aux Heat Out 046.0% ESC
SP ESC

AUX RTD SET POINT (Auto) AUX RTD SET POINT (Manual)
Aux SP Cntrl: auto Aux Setpoint 23.0°C
Aux SP Cntrl: manual

< ESC < ESC

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 Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

DRYER MODE
(Programmable)

PROCESS VARIABLE PROCESS VARIABLE 2 PROCESS VARIABLE 2

Air Actual 24.9°C Air Actual 24.9°C Air Actual 24.9°C
Rh Actual 50.1 % Rh Actual 50.1 % Rh Actual 50.1 %
Seg 00 Time 01:00:00 Seg 00 Time 01:00:00 Seg 00 Time 01:00:00
RUN SP OUT > < PROG CONFIG > < ALARM INFO

RUN/STOP

SET POINT OUTPUTS PROGRAM MENU ALARM CONDITION INFORMATION

Air Setpoint 25.0°C Air Heat Out 048.9% PROGRAM MENU ALARM CONDITION PGC Unit SN: xxxxxxx
RH Setpoint 50.0 % Refrig. Out 050.1% No Alarm Firmware ver. xxxx
Seg 00 Time 01:00:00 Dryer Output 000.0% Alarm Delay 00:00:20 Steady State Cascade
AUX PRGC ESC ESC SEG LOOP INIT ESC ACK RESET ESC ESC

AUX RTD PARAMETERS SEG 1 SEG 2 CONFIGURATION ACCESS

Aux Setpoint 13.7°C Air Setpoint 25.0°C Program Change: 00 Enter access code:
Aux Actual 13.7°C RH Setpoint 50.0 %
Aux Heat Out 046.0% Seg 00 Time 01:00:00 Seg 00 Time 01:00:00 █
SP ESC TAB PREV NEXT > < TAB ESC ESC

AUX RTD SET POINT (Auto) AUX RTD SET POINT (Manual) LOOP INITIALIZE PROGRAM
Aux SP Cntrl: auto Aux Setpoint 23.0°C Start at seg 01 Initialize program
Aux SP Cntrl: manual Loop from seg 20 at start segment?
Loop to seg 01
< ESC < ESC TAB ESC OK ABORT

INITIALIZE
PROGRAM

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Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

SLOW DAMPER MODE

(Steady State)
PROCESS VARIABLE PROCESS VARIABLE 2
Air Actual 24.9°C Air Actual 24.9°C
Rh Actual 50.1 % Rh Actual 50.1 %

SP OUT > < ALM CONFIG INFO

SET POINT OUTPUTS ALARM CONDITION INFORMATION

Air Setpoint 25.0°C Air Heat Out 048.9% ALARM CONDITION PGC Unit SN: xxxxxxx
Rh Setpoint 50.0 % H2O Heat Out 020.0% No Alarm Firmware ver. xxxx
Air Damp Out 058.0% Alarm Delay 00:00:20 Steady State SlowDmp
TAB WATER AUX ESC ESC ACK RESET ESC ESC

CONFIGURATION ACCESS
WATER PARAMETERS AUX RTD PARAMETERS
Enter access code:
H2O Setpoint 12.7°C Aux Setpoint 13.7°C
H2O Actual 12.8°C Aux Actual 13.7°C █
H2O Heat Out 49.3% H2O Heat Out 046.0% ESC
ESC SP ESC

AUX RTD SET POINT (Auto) AUX RTD SET POINT (Manual)
Aux SP Cntrl: auto Aux Setpoint 23.0°C
Aux SP Cntrl: manual

< ESC < ESC

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 Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

SLOW DAMPER MODE

(Programmable)

PROCESS VARIABLE PROCESS VARIABLE 2 PROCESS VARIABLE 2

Air Actual 24.9°C Air Actual 24.9°C Air Actual 24.9°C
Rh Actual 50.1 % Rh Actual 50.1 % Rh Actual 50.1 %
Seg 00 Time 01:00:00 Seg 00 Time 01:00:00 Seg 00 Time 01:00:00
RUN SP OUT > < PROG CONFIG > < ALARM INFO

RUN/STOP

SET POINT OUTPUTS PROGRAM MENU ALARM CONDITION INFORMATION

Air Setpoint 25.0°C Air Heat Out 048.9% PROGRAM MENU ALARM CONDITION PGC Unit SN: xxxxxxx
RH Setpoint 50.0 % H2O Heat Out 050.1% No Alarm Firmware ver. xxxx
Seg 00 Time 01:00:00 Air Damp Out 030.0% Alarm Delay 00:00:20 Steady State Cascade
H20 AUX PRGC ESC ESC SEG LOOP INIT ESC ACK RESET ESC ESC

SET POINT AUX RTD PARAMETERS SEG 1 SEG 2 CONFIGURATION ACCESS

H2O Setpoint 12.7°C Aux Setpoint 13.7°C Air Setpoint 25.0°C Program Change: 00 Enter access code:
H2O Actual 12.8°C Aux Actual 13.7°C RH Setpoint 50.0 %
H2O Heat Out 49.3% Aux Heat Out 046.0% Seg 00 Time 01:00:00 Seg 00 Time 01:00:00 █
ESC SP ESC TAB PREV NEXT > < TAB ESC ESC

AUX RTD SET POINT (Auto) AUX RTD SET POINT (Manual) LOOP INITIALIZE PROGRAM
Aux SP Cntrl: auto Aux Setpoint 23.0°C Start at seg 01 Initialize program
Aux SP Cntrl: manual Loop from seg 20 at start segment?
Loop to seg 01
< ESC < ESC TAB ESC OK ABORT

INITIALIZE
PROGRAM

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Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

TEMPERATURE ONLY MODE

(Steady State)
PROCESS VARIABLE PROCESS VARIABLE 2
Air Actual 24.9°C Air Actual 24.9°C
* *
SP OUT > < ALM CONFIG INFO

SET POINT OUTPUTS ALARM CONDITION INFORMATION

Air Setpoint 25.0°C Air Heat Out 048.9% ALARM CONDITION PGC Unit SN: xxxxxxx
Refrig. Out 048.9% No Alarm Firmware ver. xxxx
* Alarm Delay 00:00:20 Steady State TmpOnly
TAB AUX ESC ESC ACK RESET ESC ESC

CONFIGURATION ACCESS
AUX RTD PARAMETERS
Enter access code:
Aux Setpoint 13.7°C
Aux Actual 13.7°C █
Aux Heat Out 046.0% ESC
SP ESC

AUX RTD SET POINT (Auto) AUX RTD SET POINT (Manual)
Aux SP Cntrl: auto Aux Setpoint 23.0°C
Aux SP Cntrl: manual

< ESC < ESC

* Variable display line. Temperature only mode may be configured to show RH on units with an RH sensor, as
well as different outputs for some applications.

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 Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

TEMPERATURE ONLY MODE

(Programmable)

PROCESS VARIABLE PROCESS VARIABLE 2 PROCESS VARIABLE 2

Air Actual 24.9°C Air Actual 24.9°C Air Actual 24.9°C
* Seg 00 Time 01:00:00
* Seg 00 Time 01:00:00
* Seg 00 Time 01:00:00
RUN SP OUT > < PROG CONFIG > < ALARM INFO

RUN/STOP

SET POINT OUTPUTS PROGRAM MENU ALARM CONDITION

Air Setpoint 25.0°C Air Heat Out 048.9% PROGRAM MENU ALARM CONDITION PGC Unit SN: xxxxxxx
Refrig. Out 060.0% No Alarm Firmware ver. xxxx
Seg 00 Time 01:00:00 * Alarm Delay 00:00:20 Steady State Cascade
AUX PRGC ESC ESC SEG LOOP INIT ESC ACK RESET ESC ESC

AUX RTD PARAMETERS SEG 1 SEG 2

Aux Setpoint 13.7°C Air Setpoint 25.0°C Program Change: 00 Enter access code:
Aux Actual 13.7°C
Aux Heat Out 046.0% Seg 00 Time 01:00:00 Seg 00 Time 01:00:00 █
SP ESC TAB PREV NEXT > < TAB ESC ESC

AUX RTD SET POINT (Auto) AUX RTD SET POINT (Manual) LOOP INITIALIZE PROGRAM
Aux SP Cntrl: auto Aux Setpoint 23.0°C Start at seg 01 Initialize program
Aux SP Cntrl: manual Loop from seg 20 at start segment?
Loop to seg 01
< ESC < ESC TAB ESC OK ABORT

INITIALIZE
PROGRAM

* Variable display line. Temperature only mode may be configured to show RH on units with an RH sensor, as
well as different outputs for some applications.

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Parameter Generation & Control Revision F June 2012 Smart Pad Operation Manual

CONFIGURATION MENUS

SYSTEM CONFIGURATION 1 SYSTEM CONFIGURATION 2

System Configuration System Configuration

MODE ALARM TUNE > < SETUP CAL ESC

CONTROL MENU ALARM MENU ALARM CONDITION ADVANCED MENU

CONTROL MENU ALARM MENU TUNE MENU System Configuration
Control Mode Gen Alarm Config Air Temp Control Enter Advanced Code
Rh Cascade Alarms Disabled Proportional 05.00 █
< > Change Enter < > Change Enter < > Enter ESC

CONTROL CHANGE SETUP MENU

Change unit SETUP MENU
control method? Security
Access Code 0000
YES NO < > ESC

CALIBRATION MENU 1 CALIBRATION MENU 2

CALIBRATION MENU CALIBRATION MENU

AIR RH > ESC WATER AUX < ESC

AIR CALIBRATION RH CALIBRATION WATER CALIBRATION AUXILIARY CALIBRATION

AIR CALIBRATION AIR CALIBRATION WATER CALIBRATION AUX CALIBRATION
Air Actual 25.0°C RH Actual 50.0°C H2O Actual 15.0°C Air Actual 25.0°C
Ref. Value 24.6°C Ref. Value 49.6°C Ref. Value 14.6°C Ref. Value 24.6°C
ERASE ADJUST ESC ERASE CAL ADJUST ESC ERASE ZERO SPAN ESC ERASE ZERO SPAN ESC

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PGC Inc. SmartLog Version 3.0.7 January, 2013

SmartLog
Version 3.0.7

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PGC Inc. SmartLog Version 3.0.7 January, 2013

© 2013 Parameter Generation and Control, Inc. All rights reserved.

No part of this publication may be reproduced, transmitted, transcribed, stored in a

retrieval system, or translated into any language in any form by any means without the
written permission of Parameter Generation and Control, Inc., at 1054 Old US 70 West,
Black Mountain, NC 28711. (828) 669-8717.

www.humiditycontrol.com

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PGC Inc. SmartLog Version 3.0.7 January, 2013

SmartLog Version 3.0.7

DESCRIPTION........................................................................................................................... 5
GETTING STARTED ................................................................................................................ 6
System Requirements ............................................................................................................. 6
Install SmartLog ..................................................................................................................... 6
Uninstall SmartLog................................................................................................................. 6
Connecting to the Serial Port .................................................................................................. 6
Communication Control ......................................................................................................... 7
Switching Versions ................................................................................................................. 7
MAIN FEATURES ..................................................................................................................... 8
Configure Smart Pad............................................................................................................... 8
Live View ............................................................................................................................... 8
Graph Properties ..................................................................................................................... 9
Change Variable Axis Assignment ....................................................................................... 10
Large Display........................................................................................................................ 10
Mouse Functions................................................................................................................... 10
Status Indicators.................................................................................................................... 11
Temperature Unit Selection .................................................................................................. 12
Show Samples....................................................................................................................... 12
Log ........................................................................................................................................ 12
Notes ..................................................................................................................................... 13
Viewing a Log File ............................................................................................................... 14
Exporting and Printing Log Data .......................................................................................... 14
Backup Screen Data .............................................................................................................. 15
Command Line ..................................................................................................................... 15
Tune ...................................................................................................................................... 17
Alarm .................................................................................................................................... 18
Program ................................................................................................................................ 19
Hold For Control................................................................................................................... 20
Program Change ................................................................................................................... 21
Print ...................................................................................................................................... 22
Log File Auto-Generation..................................................................................................... 22
Auto-generated E-mails ........................................................................................................ 23
E-mailing Log Files .............................................................................................................. 24
E-mail in an Alarm Condition .............................................................................................. 24
Testing E-mail Functionality ................................................................................................ 24
ADVANCED FEATURES ....................................................................................................... 26
Advanced Settings Window.................................................................................................. 26
Setup and Control ................................................................................................................. 26
Tune Menu ............................................................................................................................ 31
Fault Labels .......................................................................................................................... 32
RTD Calibration ................................................................................................................... 33
COM Test ............................................................................................................................. 34
TROUBLESHOOTING ............................................................................................................ 35
SmartLog Will Not Open...................................................................................................... 35

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PGC Inc. SmartLog Version 3.0.7 January, 2013

Unable to Open COM Port ................................................................................................... 35

Unable to Connect When Using a USB to Serial Converter ................................................ 35
Connection to the Smart Pad Is Not Detected ...................................................................... 35
Certain Functions Disabled................................................................................................... 36
Only Program Option Is Disabled ........................................................................................ 36
Type Mismatch Error ............................................................................................................ 36
Error Opening A File ............................................................................................................ 37
Can’t Change Water Set Point or Rh Set Point .................................................................... 37
Can’t Send E-mails ............................................................................................................... 37

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PGC Inc. SmartLog Version 3.0.7 January, 2013

DESCRIPTION

SmartLog is a Windows-based program created by PGC to interface with PGC

conditioning units. Its many features include displaying, graphing, printing, and logging
real time data, remote configuration and control, tuning, creating automated profiles, and
advanced troubleshooting capabilities. The time-stamped log files can be configured to
record up to twenty variables at a time and may be opened and analyzed in graphical or
text format, and data may be exported to a text file or printed for archive. Log files are
defaulted to text format but also may be configured to be encrypted.

SmartLog uses a very simple serial connection to the Smart Pad, and can be up and
running in moments. Multiple units may be monitored at once by opening multiple
instances of SmartLog as long as there is a devoted serial port for each opened window.

The user is recommended to read this entire document to be familiarized with the specific
uses of the software. If you have any further questions regarding this software please feel
free to contact our technical support for this product by phone at (828) 669-8717 or by
email to service@humiditycontrol.com.

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PGC Inc. SmartLog Version 3.0.7 January, 2013

GETTING STARTED

System Requirements

SmartLog will run on Windows 95/98, 2000, XP, Vista, and 7. The system must have a
processor speed of at least 300MHz with 256MB of RAM for optimal performance.
10MB of hard drive space is required for the installation, and more will be required as log
files are generated and stored. SmartLog will interface to any Smart Pad firmware
version, but for full compatibility, Smart Pad firmware version 502a or higher is required.
If you have an older version and would like to upgrade, the latest version of SmartLog
may be found on our website at www.humiditycontrol.com/references.php .

Install SmartLog

Unzip the PGC SmartLog.zip file. Double-click on the PGC SmartLog.msi file and
follow the instructions to load SmartLog onto your computer.

Uninstall SmartLog

The best way to remove SmartLog from your computer is to access Add/Remove
Programs program located in the Control Panel on your computer. If you have used the
install wizard to load SmartLog on your machine, then SmartLog will appear in the list of
programs shown in this window. Click Remove and the uninstall will begin.

Connecting to the Serial Port

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PGC Inc. SmartLog Version 3.0.7 January, 2013

1. Connect a DB9 serial cable (no longer than 50ft) from the desired serial port on your
computer to the serial port on the PGC controller. Distances greater than 50ft will require
more advanced hardware options (contact a PGC representative for more details). Make
sure it is not a null modem cable, as null modem cables reverse the send and receive lines
and will therefore make communication impossible. Many computers are not equipped
with RS232 serial ports; however, there are many USB to RS232 converters on the
market, many of which create several COM ports with one USB connection.

2. Turn on your PGC conditioning chamber or air handler and wait for the Smart Pad to
connect to the ACE controller. It will flash "Connecting" on the bottom of the screen
until it has established internal communication.

3. Once data is seen on the Smart Pad screen, SmartLog may be opened. If the Select Port
window does not open automatically, select the desired COM port under the Configure
menu (Configure > COM Port). A list will be generated which includes all available
ports and of those ports which are connected to a unit. If a USB to RS232 converter has
created COM ports higher than the standard 16, SmartLog can be configured to poll more
ports in the Advanced Settings window.
Select the desired port and click OK, or simply double-click on the desired port. A
small “Connect” indicator at the bottom of the screen will turn from red to green when
communication with a Smart Pad is established.

Communication Control

If SmartLog is to be used without a serial connection, for instance to view a log file
offline, it will be desirable to end communication attempts. Attempting communication
without a response requires much more processing power than when there is a
connection. In this case, the communication indicator in the bottom-left of the main
window will be red. To turn off the communication, simply press F4, or choose
Communication>Disconnect from the Configure menu. When the communication
indicator turns dark red, communication has been turned off.

Switching Versions

In order to use the CFR Part 11 compliant version of SmartLog, you must obtain a
registration key from PGC, which is specific to your unit’s serial number. If you have
already started using the basic version, you will have to uninstall SmartLog and install it
again to reach the Startup Window, where you may choose to proceed to the CFR Part 11
compliant version. Conversely, if you have been using the CFR Part 11 compliant
version and would like to use the basic version, the same procedure will be required.

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PGC Inc. SmartLog Version 3.0.7 January, 2013

MAIN FEATURES

Configure Smart Pad

Smart Pads with firmware versions of 501 or later may be

configured remotely. The Smart Pad configuration
window may be accessed under the Configure Menu or
by pressing F7. From this window, you may change the
control mode or set point entry mode (Programmable or
Steady State). If your machine is equipped with the soft-
start feature, you may turn the unit on and off as well.
This window also displays the serial number and
firmware version for your Smart Pad. Further
configuration is available in the Advanced Settings
window. Call PGC for information on upgrading Smart
Pad firmware.

Live View

You may monitor the conditions of the machine both

numerically and graphically. To view the current
process values, select Current Data under the View
menu. If the controller is configured for steady state set
point entry (not programmable) you can modify the set
points from this window. Any set point that is not
accessible (e.g. water set point when operating in
cascade mode) will be grayed out, and cannot be
changed. The auxiliary RTD reading will be displayed
in the bottom-right corner of this window only if
SmartLog is polling for it (see Command Line).

Under the Graph menu, select the variable you

would like to display, or select All Variables
which will display them all. Clicking on a
variable will deselect it. The outputs and Rh are
expressed in percent, so their values are oriented
to the right y-axis; temperatures correspond to
the left axis. Dryer Output and Auxiliary
Temperature are values that only exist in
select units. Therefore, SmartLog does not
poll for these values unless they are checked.
See Command Line.

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PGC Inc. SmartLog Version 3.0.7 January, 2013

Each variable has a unique color. To familiarize yourself with the colors, select Legend
from the View menu.

When the live view scroll bar is visible, you may scroll back to view earlier events. This
feature is limited to a maximum of around 32000 samples. A slower sample rate will
yield a longer live view because it will reach the critical number of displayable points
over a longer period of time. The earliest point viewable on the graph at any time will be
displayed on the bottom-right corner of the screen, labeled “Start:”.

Graph Properties

To change the scale of the display or the sample

rate at which you would like to receive data,
select Properties from the Graph menu or
double-click on the graph.

Sample rate determines how often SmartLog

will request data from the Smart Pad. The
sample rate may be any value from two seconds
to ten minutes. Faster sample rates can yield
more data than may be desired (large files), but
slow sample rates can miss important subtle
changes. Ten seconds is the default value.

The Time Divisions scroll bar determines the

distance between vertical dividers on the screen,
and the Timeline scroll bar determines the total
time span shown on the graph. There are two
shortcut scroll buttons that allow incrementing
the timeline by hours or days.

The maximum and minimum limits for both the left and right axes can be configured.
The Minor Div. field will adjust the horizontal divisions on the graph.

The Graph File Resolution scroll bar determines the trace resolution when viewing a
logged file. Lower resolutions may be desired to speed up the process of loading a large
amount of data, such as viewing a file with a timeline of several days.

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PGC Inc. SmartLog Version 3.0.7 January, 2013

Change Variable Axis Assignment

The default assignments for variable traces are defaulted to temperatures on the left y-
axis, and percent on the right y-axis, for RH or output percentage. In some cases, it may
be beneficial to assign a variable to the other axis. To do this, open the Graph Properties
Window (double-click anywhere on the graph) and click on the Axis Configuration
button (see preceding image). This will display the window that allows the user to
reassign the variables. Checked boxes indicate assigned axes. Click OK to accept the
assignment changes, or Cancel to exit without changes.

One possible application of this feature could be to display the air temperature
NOTE and water spray temperature on two different scales. This would allow very
detailed graphs of both variables.

Large Display

The current process variables (Air and Rh or

Air and Water) can be displayed in bold
characters on the live view. Select View >
Large Display > Large Variable Display to
enable.

Select View > Large Display > Heavy Lines to

increase the thickness of the traces in the live
view.

Mouse Functions

Left Click-and-Hold - Shows temperature,

date/time, and percent at the mouse pointer
coordinates. To determine the air temperature at a
given point, for example, click on a point in the air
trace (red line), and the value will be displayed in a
text window beside the mouse pointer.

Right Click-and-Hold - Shows standard log

variable values at the mouse pointer x coordinate.
This is useful for comparing multiple parameters
values at the same sample time.

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PGC Inc. SmartLog Version 3.0.7 January, 2013

Shift + Left Click - Measures temperature or

percent difference as well as elapsed time from one
point to another (changes in x and y coordinates) on
the graph. Press shift and click on first point and
drag to the second point while holding down the
shift key to view the time elapsed between the two
points.

Status Indicators

There are five status indicator icons which are found at the bottom-left corner of the main
window (see diagram). When the mouse rolls over the status indicators, a text box will
appear displaying its function.

Connection Status - Shows the status of the serial port connection. If the indicator is
green, SmartLog is communicating with the Smart Pad; if it is red, SmartLog is
attempting communication but there is no response; if it is dark red, the serial port is not
open and no communication attempts are being made. Pressing F4 will toggle between
disconnecting and attempting a new connection.

Unit run status - Shows yellow if the unit is running and dark red if the unit is in
standby. Double-clicking on the indicator will turn the unit on or off.

Logging Status - Becomes visible only when logging to a file. This helps distinguish
from logging to a file and viewing an open file.

Low Temperature Mode Status - Visible when Low Temperature Mode is active. In
low temperature mode, lower temperatures are achieved by eliminating or limiting water
temperature control. For a full description of when Low Temperature Mode is used and
if it is available in your unit, consult your product manual.

Alarm Status - Blinks on and off in the event of an alarm or fault condition. To examine
what alarm has tripped, click on the indicator, and the alarm configuration window will
appear. See Alarm for more information.

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PGC Inc. SmartLog Version 3.0.7 January, 2013

Temperature Unit Selection

Though the Smart Pad can only display temperatures and accept set points in Celsius,
SmartLog may be set up to monitor and log data in Fahrenheit. To select whether the
temperatures are displayed and logged in Celsius or Fahrenheit, check the desired unit in
the Temperature Units portion of the Configure menu.

Show Samples

The Show Samples option allows you to see each data point
received from the Smart Pad. This feature is especially
useful in determining what the sample rate was in a file or if
the unit was powered off or not responding during a given
time period.

Log

Logging may be initiated by selecting OK in the popup

message box at startup or by selecting Log to File from
the File menu. If you would like to be prompted to log
at the start of the program, select Prompt to log at
startup from the File menu. The log option will log the
six commands selected in the command line (see
Command Line).

Log files consist of an information note at the

beginning, consisting of tuning information and other
settings, a heading line, and the data lines, which
consist of a Windows-formatted time and the six log
variables. If communication is temporarily lost
between the PC and Smart Pad, data points may be lost.
In this case, the log file will contain "--.--" as a
placeholder for lost data.

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PGC Inc. SmartLog Version 3.0.7 January, 2013

Notes

The NOTES option allows the user to make

notes about events in the process. To create a
note, press shift while right clicking on the
graph at the event where you would like to
leave a note. A small blue marker will appear at
the top of the screen, with a note box prompting
you for a message. Type the note in the box and
double-click to save. The note will be time-
stamped with the time it was created. To display
the saved note, move the mouse over the
marker. To stop displaying the note, click
anywhere on the graph display. Notes may be
deleted by right-clicking the marker.

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Viewing a Log File

To view a log file in graphical format, select Open File from the File menu. A window
will appear with checkboxes for choosing which variables to display. Once a file is
loaded, traces may be added or removed from the view by selecting or deselecting them
from the Graph menu. Each file will have a note stored at the beginning detailing the
tuning values and other settings stored in the Smart Pad at the onset of the log. If a file
takes a long time to load, you may change the graphing resolution with the Graph File
Resolution scroll bar under Graph > Properties.

If you would like to open a file with no connection to the Smart Pad, select Configure >
Communication > Disconnect from the Configure menu or press F4.

A log file may also be viewed in text format by selecting Source Data from the View
menu. If a file is currently open for viewing or logging, the text base for that file will
appear. If no file is open, you will be prompted to choose a file to view.

Exporting and Printing Log Data

Log data is normally stored in an encrypted format, but data may be exported to a text file
from the Source Data window by clicking Export Data under the File menu. This allows
the data to be imported into a spreadsheet program such as Microsoft Excel. The log file
is comprised of a starting note which outlines the Smart Pad settings, a header line,

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labeling the rows of data, followed by the rows of data consisting of a time, the six log
variables, and occasional notes, which are denoted by “*” followed by the note.

Since the notes are not intelligible data to a spreadsheet program, SmartLog offers the
option to filter the notes from the output text file or print document by checking Hide
Comments For Export/Print under Filter. Once this item is checked, the notes will not
appear in an exported text file or in a printed log file document.

Log data may be printed by selecting Print under the File menu. A dialog will become
visible which allows you to choose the printer and gives the option of printing duplex.
Each page of the resultant document will be headed with date and time of printing, file
title, page number, and, in the CFR Part 11 compliant version of SmartLog, the current
user.

Backup Screen Data

The data used to create the live view are stored in temporary buffers and may be saved
directly to a log file. This will be useful if a log has not been initiated and the user would
like to save the screen data. This is achieved by choosing Backup Screen Data from the
File menu. The data will be saved in the same format as a log file. Although no further
data can be appended to the file, the log will contain approximately the last 32,000
samples of data. Logging of additional data should be accomplished by selecting Log to
File and creating a new log.

Command Line

The eight Command Line variables

determine which parameters are available
to be graphed and displayed. These are
accessed by pressing F12, or by selecting
Command Line under the Configure
menu.

The commands sent to the Smart Pad are

listed in the left column (refer to the
Smart Pad manual for a complete list of
the Smart Pad’s terminal commands).

The labels to the right-hand column

describe the commands listed in the left-
hand column. These labels become the
parameter labels listed under the Graph
menu (see previous page). Use caution when changing the parameter or label to ensure
they match.

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At startup, SmartLog will log eight variables. The user can choose to log between six
and twenty variables at a time. The user may choose how many variables are logged with
by using the up and down arrows. Clicking the down arrow adds another poll command
to the command line and clicking the up arrow will subtract one command from the
command line. The header line in a log file will correctly indicate the variables that are
being logged as long as the log file is initiated after the command line has been modified.

The following is a partial list of available commands:

Set Point (°C) Measured Value Output (%)

Air ?AS ?AP ?AO
Water ?WS ?WP ?WO
Rh ?RS ?RP n/a
Aux Heat ?XS ?XP ?XO
Dryer n/a n/a ?RO
Damper n/a n/a ?DO

When the View Command Line check box is selected, a window listing the currently
monitored parameters becomes visible. This window shows all communication between
SmartLog and the Smart Pad as well as the COM port being used. See the Smart Pad
Manual for more details on the Smart Pad terminal program. The command line
window may also be viewed by clicking on the connection indicator in the bottom-
left corner of the main SmartLog window.

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Virtual Commands

There are three commands that can be entered into the command line that are never sent
to the Smart Pad. Instead, those commands are locally handled by SmartLog. Using
these commands, SmartLog is able to display and log dewpoint, standard deviation, and
sigma (See Tune).

Virtual Command Description

?DP Calculates dew point.
?SD a bb.bb Calculates standard deviation.
?SG a bb.bb cc.cc Calculates sigma, a variation of standard deviation.

It is important that the command is entered in the exact format Process Variable
provided in the above table. The components of the commands are Air Temperature 0
separated by solitary spaces. The first variable, a, in the standard Relative Humidity 1
deviation and sigma commands signifies the process variable. The Water Temperature 2
second term, bb.bb, signifies the sample time for the standard Air Output 3
deviation given in hours, and the third, cc.cc, in the sigma command Water Set Point 4
signifies the desired tolerance of the variable. For instance, the Water Output 5
standard tolerance for relative humidity in a PGC machine is +/- Dryer Output 6
0.5%, which would be represented as “00.50” here. Aux. Temperature 7

Example The command for calculating sigma for relative humidity over 2.5 hours at a
tolerance of +/- 0.5 would be entered as follows: ?SG 1 02.50 00.50

Tune

Although the process variable tuning parameters (Control Band, Rate, and Derivative)
have been preset at the factory to optimize the performance of your machine, you may
change the set points and tuning parameters in the Tune window under the View menu. It
is important to note that altering these values can easily cause the operation to
become unstable.

Standard Deviation, or the statistical spread of the data, is calculated for the variable
selected in the process variable option box. The time over which the standard deviation
is calculated may be changed under Sample Time. Alternatively, clicking on Pick points
for Std Dev. allows the user to manually choose the sample area on the graph. When this
alternative method is used, the View picked Std Dev box becomes automatically checked
in order to “freeze” the displayed Tolerance, Std Dev., and Sigma values. Uncheck the
box in order to see the most current automatically-calculated values. Some users find
Sigma, a close relative of the standard deviation, to be a more helpful number, due to its
relation to process variable tolerance. Sigma equals tolerance divided by standard
deviation.

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Alarm

The Alarm window may be accessed under the Configure Menu or by clicking on the
bell-shaped alarm indicator which flashes at the bottom of the screen during an alarm
condition. From this window, you may change the limits or deviation values that
determine what trips the alarm. An alarm may be configured to trip by limits or
deviation, but not both simultaneously. You may also enable or disable the alarm, as well
as change the alarm timer value, which controls the amount of time before the alarm is
activated during an alarm condition. Resetting or acknowledging an alarm may only be
executed from the Smart Pad. Refer to your Smart Pad manual for more specific
information regarding the alarm function.

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The alarms may be monitored constantly with this window closed if the “Monitor
Alarms” checkbox is checked. This selection adds the command that polls for alarm data
to the list of commands sent to the Smart Pad each sample time. If an alarm or fault is
set, and the Alarms window is open, the background of the right-hand side of the window
will turn red and the Alarm Conditions list box will show the current alarms and/or faults.

Program

If your Smart Pad is configured for Programmable mode, it is able to control set points
via a user-defined program of up to 40 segments (00 through 39). Each segment changes
air, water, or Rh set points to a new value over a specified length of time. The user is able
to define the start, stop and looping parameters for a program cycle. Each programmed
dwell requires two segments: one segment to determine the time required to change from
the current set point to the new set point (RAMP); another segment to establish how long
the controller will remain at that set point (DWELL).

To view and edit the current program, make sure your Smart Pad is in Programmable
mode. To access Programmable mode from SmartLog, choose Smart Pad under the
Configure menu window or press F7. Once open, click on Programmable mode, and the
Smart Pad should automatically restart in Programmable mode.

Select Program from the View menu in SmartLog to see the entire program stored in the
Smart Pad. From this window, you are able to setup each segment in the program, as well

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as the loop parameters. The Configure Smart Pad window is not available for Smart
Pad versions prior to version 501.

A solid line in the program display represents the change of a set point over time. A
dotted line represents a change that happens only one time. For instance, during a starting
segment, the set point will ramp from wherever it is when the program was started. This
is represented by a straight horizontal dotted line. The other event that will happen only
once is when a set point from a non-loop segment ramps into a loop segment.

The user may also save and open Smart Pad programs. This is done by selecting Save
Profile or Open Profile from the File menu.

The left and right axes in the program view

screen can be customized for your application.
Access this window by double-clicking on the
program screen or by choosing Graph >
Properties. In this view the left and right y
scale can be changed and the horizontal
gridlines may be mapped to either the left or
right scales.

Hold For Control

Clicking on the checkbox marked Expand will expand the view of the program window
to include Hold For Control and Program Change.

When the Hold For Control checkbox is checked for a given segment in a program cycle,
SmartLog instructs the Smart Pad to halt the program until the selected condition has
achieved a value specified by the Control Tolerance text box. The user may choose to
hold for air temperature or Ch2, which will be relative humidity in Rh Cascade Mode and
water temperature in Two Temperature Mode. The selected process variable will come

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into “control” when it reaches its set point +/- the user-specified control tolerance. Until
the process variable reaches the control tolerance the Smart Pad program will be halted
and the run indicator will indicate a Hold For Control condition by turning from green to
a blinking orange and dark red. Each segment on the program display graph with Hold
For Control enabled will be identified by a small blue marker at the top of the graph, and
a note will be added to the live display each time the program is automatically halted or
restarted.

As with programming set points and segment time, you must click the Set command
button after setting up a Hold For Control condition. Hold For Control data will be saved
to a file along with segment data.

Unlike Program Change, Hold For Control is a feature that resides solely in SmartLog.
The Smart Pad doesn’t “know” that it is going to halt the program until a variable gains
control. As a result, if the Program Window is closed during a program cycle with Hold
For Control, the program will run continuously.

Program Change

The Program Change option allows you to change the control mode and the values of
auxiliary outputs automatically when a segment is reached. You must change the
Program Change values for a specific segment and then press Set to write those changes
to the program segment in the Smart Pad. The number marked “Value:” is the code that
would be entered manually into the Smart Pad for the current Program Change (See
Smart Pad manual for Program Change codes).

To automatically change the control mode, select the segment for which you would like
to change modes by clicking on the segment on the program graph or by navigating with
the prev and next command buttons. Then select one of the four mode options in the
Mode Change section and press Set to write the change to the Smart Pad. It is only
necessary to make this selection once. For example, if you would like the machine to be
in Two Temperature Mode for segments 3-6, it is only necessary to set the mode change
to “To Two Temperature” for segment 3. The control mode will not change
automatically for the start segment; instead, the Smart Pad must be set up in the
appropriate control mode at the onset of the program cycle.

A small red indicator will note the location of a program change at the top of the segment
on the graph.

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The Program Change option also allows for three possible auxiliary outputs. If an output
checkbox is selected and Set is clicked, then the output will be energized when the
selected segment is reached in the program. Auxiliary outputs are for hardware
options that only exist on select machines. Most users will not use this function.

Print

You may print any open file, live view, or Smart Pad program. When printing, each trend
line will be labeled with a leader line and text box to indicate the value being represented.
This is especially useful when printing to a black and white printer. Each live view
printout will display the file name; date, time, sample rate, timeline and time divisions.
Each program view printout will display file name, date and time. The print commands
automatically print to your default printer with no additional page formatting required.

Log File Auto-Generation

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Log files may be generated using the Auto Generate Files option under the File menu.
This feature allows you to continuously log data to a file, but break the files up into days
or weeks. This allows individual file size to be more easily manageable and for events to
be easier to find.

Choose the path to which all log files will be saved by clicking Browse. A Windows
Save dialog window will appear. The file name is automatically generated including the
unit serial number, current date, and time in non-punctuated 24-hour time. Once a path is
selected, choose the file generation frequency and the time new files should be started.
The longest period allowed for one file is 7 days. Clicking on the Begin Log command
button will initiate the first log file. The Auto-Generate window may be closed or left
open—file regeneration will resume regardless.

Log information will appear in the bottom portion of the Auto-Generate Window. These
four lines will show whether a log file is open, if files are being automatically generated,
when the next file is due to be started, and how many log files have been generated
altogether. Once the system is logging, clicking on the Stop Log command button will
close the current log file and disable file auto-generation.

Auto-generated E-mails

SmartLog may be configured to send e-mails automatically for the purpose of keeping
logging records, monitoring conditions remotely, or for monitoring alarm or fault
conditions. There are two e-mail options: an e-mail may be sent each time a log file is
generated when using log file auto-generation or when there is an alarm or fault
condition.

SmartLog does not use existing e-mail client software (e.g. Microsoft Outlook); instead it
becomes an independent e-mail client, connecting directly to your SMTP server. The
SMTP server is what routes e-mails to their destinations, and is either part of your
internet service or part of your local network in the case that you have Microsoft
Exchange Server on your network. To send e-mails through it, you must provide
SmartLog with the numerical IP address of the SMTP server, which may be obtained
by contacting your internet service provider or your IT technician. The IP address must
be typed into the text box labeled “SMTP Server” the first time an e-mail is sent, and
SmartLog will remember the IP address from then on.

Auto-generated e-mails may be used to distribute information to coworkers and

customers, but they may also be monitored by PGC service technicians if a monitoring
contract is purchased. Contact PGC for further details and pricing.

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E-mailing Log Files

When log file auto-generation is enabled, log files are sent via e-mail each time a new file
is created. Up to five e-mail addresses may be designated as recipients of periodic log
files. When a new file is created by the auto-generation feature, SmartLog will send the
last log file to only the addresses marked with a checkbox in the column for e-mailing log
files, which is marked with a page symbol. Blank recipients or unchecked recipients will
be ignored, and incorrect e-mail addresses will be handled by error messages. The
recipient name text box is only for personal identification use and is not used by the
program.

E-mail in an Alarm Condition

SmartLog will also automatically send e-mails in the event of an alarm condition. The
checkboxes that control the alarm e-mail feature are in the column marked with a small
red bell in the log file auto-generation window. If the alarms are enabled in the Smart
Pad and a parameter goes out of range, the screen on the Smart Pad will flash and the
alarm output on the ACE controller will be set. If an alarm e-mail box is checked during
the alarm condition, an e-mail will be sent automatically to the recipient to the right of
that check box. If both boxes are checked beside an e-mail recipient, the recipient will
receive an e-mail when the next log file is generated and whenever there is an alarm
condition.

In some cases, such as when e-mails are sent to cell phones, it may be desirable to send
multiple e-mails until the alarm is addressed. At the bottom of the Auto-generation
window the user may choose the number of e-mails to be sent during an alarm condition
and how long to wait between each e-mail.

Testing E-mail Functionality

Log email test button

Alarm email test button

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Rather than instigating an alarm condition or waiting for a log file to auto-generate, there
is another way to make sure the correct SMTP IP address has been chosen and that you
are able to send e-mails. Press shift and click on the background of the Auto-generate
window and a pair of command buttons will appear beneath the e-mail check boxes. The
button on the left tests the alarm e-mail function, while the button on the left tests the log
e-mail function. Prepare the SMTP IP address, the sender name and address, and the
recipient address (your e-mail address for test purposes). Also remember to check the
boxes to specify which recipients will receive e-mails. When you click on a test e-mail
command button a message box will pop up that reads “Message Sent”. Check your
inbox to make sure you have received the e-mails. When finished testing, press shift and
click on the left side of the Auto-generate window to make the command buttons
disappear.

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ADVANCED FEATURES

Advanced Settings Window

The Advanced Settings Window may be accessed by choosing Advanced Settings under
the Configure Menu, or by pressing Alt+Backspace. This window allows the user to
change settings in the Smart Pad and in SmartLog to change the behavior of the system.
It is also the control center with which all user accounts and security features are
managed.

Setup and Control

The Setup and Control tab is used for controlling several crucial Smart Pad and ACE
controller settings as well as SmartLog settings. Serial number and Firmware version
number are read-only settings.

Temperature Offset – This text box has two functions. The air sensor input value is
offset to a higher value in the ACE controller so the value will always be positive. The
Smart Pad simply removes that ACE offset so it can display the number correctly. The
standard value is -12.50, as the lowest air temperature reading in the standard temperature
range is -10.0°C. This text box may also be used to nudge the air temperature reading to
match a neighboring sensor. This offset can by no means be equated to a calibration.

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For more information on air/rh calibration, consult your product manual. The scroll
arrows to the right nudge the offset by hundredth degree increments, and the arrows on
the right scroll between common PGC offsets.

Asp-wsp min diff. – This text box controls the minimum allowable difference between
the air and water set points. Certain high humidity conditions under controlled
circumstances can take advantage of a smaller difference between these set points.
However, it is important to note that the reason the difference is there is to prevent air
saturation in the conditioned area. Air saturation can be detrimental to the rh sensor, not
to mention the product being conditioned.

LT Switch Point/Dead Band – Low Temperature Mode allows for air temperature
control at low temperatures by taking humidity control out of the loop. The humidity
control is eliminated because for all but relatively high humidities, the water will freeze
for conditions with low air temperatures (below around 3.0°C). In short, the air
temperature is controlled by the water temperature in this mode. The Low Temperature
Mode switch point controls at what air temperature or air set point Low Temperature
Mode control is activated. The default is 3.0°C. The dead band controls how far the
temperature has to travel beyond the switch point before Low Temperature Mode is
activated. Change these values only if you are experienced or if you are working
with a member of PGC’s support staff. It is very easy to freeze the evaporator coil
using Low Temperature Mode.

Aux LT Set Point/Aux ST wsp offset – These text boxes dictate how the auxiliary
heater is controlled. Many units use an auxiliary temperature control circuit to control a
door heater to prevent condensation on the door (window). To achieve this, the
temperature of the window must be higher than the dew point of the air inside. In
Standard Temperature Mode (ST) the dew point may be approximated by the water set
point plus a small offset (Aux ST ws offset). In Low Temperature, however, there is no
water set point and thus a set value must be used for the set point (Aux LT Set Point).
The default value for Aux LT Set Point is 5.0°C.

Refresh All – Clicking on Refresh All will poll the Smart Pad for all of the settings
contained in the Advanced Settings window.

Export Settings – Clicking on Export Settings allows the user to save the settings
contained in the Advanced Settings window, as well as the tuning values, to a file. A save
dialog will appear and SmartLog will save to the created file in text format.

FWSP Enable – This checkbox enables or disables Fast Water Set Point in the ACE
controller. Fast water set point is the feature that forces the water heater output to a
maximum or minimum when the relative humidity is outside of its control band. Under
certain conditions, it can cause an RH cycle and must be disabled.

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H20 Cal – This checkbox enables or disables the ability to calibrate the water or
auxiliary temperature probes. This can be useful to prevent accidentally corrupting the
calibration.

Standby Mode Enable – Unchecking this box disables the ability to switch to Standby
Mode by pressing the Smart Pad on/off key.

Auto-Mode-Change Enable – Checking Auto-Mode-Change Enable will force the unit

into Dryer Mode whenever the air temperature or air set point dips below the Low
Temperature Switch Point. Conversely, when going above the Low Temperature Switch
Point the unit will be forced into Rh Cascade Mode.

Alarms As Faults – When this box is checked, Air and Ch2 alarms will be treated as
fault conditions; the unit will be forced into Standby Mode and the alarm condition will
be displayed on the Smart Pad. When this box is unchecked, the alarms will behave
normally. See the alarm section of the Smart Pad manual for more information. This
feature is not available on all Smart Pads.

Lock SP – When checked, the main process variable set points (usually Air/RH) will be
locked from entering new set points from the keypad.

Aux RTD SP Manual Mode – When checked, the set point for the auxiliary RTD
circuit, most commonly used for door heaters, is determined by manually entering a set
point in the Smart Pad. When unchecked, the set point is determined automatically (see
Aux LT Set Point/Aux ST wsp offset).

Reboot in Standby Mode – When checked, the unit will always reboot in standby mode
when power to the unit is cycled.

Prompt to log on Startup – When checked, a message box will prompt the user to begin
logging data to a file every time SmartLog starts up.

Prompt message on closing SmartLog – When checked, a message box will pop up
reading, “Are you sure you want to exit?”

Automatically name session – When checked, SmartLog will automatically name the
session with the serial number of the connected unit every time SmartLog starts up.

Automatically poll for Dryer Output in Dryer Mode – Since SmartLog only logs six
variables and Dryer Mode is not used as commonly as Rh Cascade Mode, the six
variables do not normally include the Dryer Output. However, when this feature is
checked, Dryer Output will replace Water Temperature, as the water temperature is not
needed in Dryer mode.

Create notes on program segment change – When this box is checked, notes will be
created when a new segment is started in a Smart Pad Profile. This feature is very useful

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if there are many conditions in a profile or if the conditions are difficult to distinguish in
the graph view without labels.

Automatically Create New Instances For Each Unit – When this box is checked and
SmartLog is opened, SmartLog will poll for connected Smart Pads and open an instance
of SmartLog for each unit. This feature, used in conjunction with the Remember
SmartLog Folders and Settings Per Unit feature, can save time in setting up SmartLog
for each unit and even allow for an unexpected computer reset with minimal

Remember SmartLog Folders and Settings Per Unit – When this box is checked,
SmartLog will recall the settings it maintained the last time a specific unit was connected.
The settings saved for each unit are: graph properties, display variables, logging status,
log path, and file auto-generation status. This feature is not available in the basic
version.

File Encryption Enable – When this box is checked, SmartLog will encrypt all data
stored in log files. These files may be opened normally in SmartLog, but not in any other
program, so data cannot be altered.

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Set Point Limits

Set point limits may be imposed on the Smart Pad to protect the unit from extreme
temperatures, or to prevent the user from entering conditions beyond the system design.
Water set points are limited to several degrees above freezing to eliminate the possibility
of any freezing on the evaporator coil, and they are often limited to one degree below the
air temperature to prevent saturation in the conditioned chamber. The Set Point Entry
Limits section of the Set Point Limits tab defines the limits of set points that are
manually entered into the Smart Pad. Air temperature and RH set point entries will be
limited in RH Cascade Mode, Dryer Mode, and Slow Damper Mode, whereas the water
set point entry will be limited only in Two Temperature Mode. RH Cascade Limits
limit the automatically cascading water set point in RH Cascade Mode and in Slow
Damper Mode, and have no bearing on set point entry.

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Tune Menu

The Tune Menu tab contains a list of possible components that populate the tune menu in
the Smart Pad. Since each control mode in the Smart Pad has different components in
their respective tune menus, the menus must be configured separately for all four control
modes. To do this, choose the option button for the desired mode in the top left corner of
the tune menu tab and check all of the values that you wish to be displayed on the tune
menu for the selected control mode. All of the components are abbreviated; mouse-over
a component to read its description. When all the selections have been made for each
menu, click save changes. The Return Code is a hexadecimal representation of the
settings, and is for PGC internal use only. In general, there should rarely be a need to
change any components in the tune menu.

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Fault Labels

The Fault Labels tab controls what message is written to the Smart Pad screen in the
event of a fault condition. Not all of the fault inputs are used in all PGC environmental
controllers, so some of the labels may read “UNUSED”. These labels would only need to
be changed if a fault input changed. Each label in the Fault Labels tab is labeled with the
default fault input for that channel. The text box below it may be changed to the desired
fault label. Note that the first label contains the word “FAULT”, and every other label
uses that part of the first label, so “FAULT” does not need to be repeated when changing
labels 2-5. Clicking Default Settings will populate the text boxes with the default label
setup.

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RTD Calibration

The RTDs may be calibrated from the Smart Pad or from SmartLog. The two-point
calibrations consist of a low component (Zero) and a high component (Span). Select
which RTD to calibrate by selecting the corresponding option button under the Calibrate
label. Both RTDs must be plugged in before calibration begins. Follow the
calibration procedure as outlined in the Smart Pad manual. After clicking Zero or Span,
the measured value (Actual) should equal the reference value next to the button that was
clicked. The Zero value must not be within 10°C of the Span value or else the calibration
will be rejected. If the calibration appears to have become corrupted, or if the readings
are grossly different from an external sensor, the Wipe Calibration button may be clicked
to remove calibration constants and restore the calibration to its default condition.
Clicking Zero, Span, or Wipe Calibration may not be undone. The prior calibration
will be lost. Incorrectly calibrated RTDs can cause damage; only use this feature if
you have a full understanding of this subject.

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COM Test

From the COM Test tab, a direct link to the Smart Pad’s terminal program may be
accessed. Type commands in the Direct to Smart Pad text box and review the response
in the Response From Smart Pad display. For more information on the terminal program,
see the Smart Pad Manual.

If devices are being used on your computer to convert to RS232, it is possible that the
COM ports may enumerate past SmartLog’s default of 16. In that case, the maximum
number of COM ports to poll on startup can be changed in the upper right corner of the
COM Test tab.

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TROUBLESHOOTING

SmartLog Will Not Open

Check your operating system compatibility (see System Requirements). Ensure that
SmartLog was properly installed with the setup wizard supplied in the original
SmartLog.zip file or setup folder.

Unable to Open COM Port

The selected COM port may already be in use by another program, may not be
functioning properly, or may be disabled.

Unable to Connect When Using a USB to Serial Converter

USB to serial (RS232) converters provide a simple solution for connecting a computer
that is not equipped with an RS232 serial port to a Smart Pad. However, they are
sometimes mapped to irregular port numbers. For instance, if there are several USB ports
on your computer, the converter could be mapped to a different COM port for each of the
USB ports. Check which port the converter is plugged into when the COM port is
originally mapped and use the same USB port each time the device is used.

It is also important to note that the appropriate driver files must be installed before the
USB to serial converter will work. The device should come with a disc that contains all
the necessary files for its use. However, if the disc is not available, most USB to serial
converter driver files are available for free download on the internet.

Connection to the Smart Pad Is Not Detected

Check the serial cable connection. If the cable is more than fifty feet long, use a shorter
cable. Make sure the cable does not have “Null Modem” written anywhere on it. Null
Modem cables have the send and receive lines switched, and will not work in this
application.

To test the cable, try the using it on another serial device or test it using the following
procedure: Plug the cable into the correct serial port on the computer. Open a terminal
emulator program, such as HyperTerminal, and set the communication parameters to
9600 baud, 8 bits of data, no parity, 1 stop bit, and flow control set to none. The other

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PGC Inc. SmartLog Version 3.0.7 January, 2013

end of the serial cable should be a female connector, and should have 9 holes, which are
very subtly marked with numbers. Bend a small wire, such as a small paper clip into a U-
shape and insert each of the ends of the wire into the holes marked “2” and “3”. This will
connect the transmit line to the receive line so any data sent out will be sent back to the
COM port. In HyperTerminal, type some characters. The characters should be mirrored
back so they can be read on the screen if the cable and the port work.

To test the connection to the Smart Pad with a good COM port and cable, open
HyperTerminal as described above. If you reboot the Smart Pad now, you should see a
message on the screen that includes software version number and control mode. Type in
“?AP” followed by carriage return (enter). You should see “?AP” on the screen, followed
on the next line by the current air temperature. If this does not happen, then it is possible
that the Smart Pad serial port is damaged or not functioning properly.

Certain Functions Disabled

(Alarm/Smart Pad Configure, Program, etc.)

Smart Pad software versions under 501 do not support these commands. If you do have
501 or greater, close and restart SmartLog. If that still does not work, there may be
problems with the connection to the Smart Pad; see Connection to the Smart Pad Not
Detected above. If you would like the option of accessing these screens, you may
consider upgrading your Smart Pad to a newer software version. In many cases, the
controller software can be retained, while upgrading only the Smart Pad controller chip.
Contact PGC for more details.

Only Program Option Is Disabled

You must first configure the Smart Pad to Programmable mode to access this screen. This
may be done by choosing Smart Pad in the Configure menu and clicking the
Programmable option on the right side of the window, or by manually changing set point
entry mode using the Smart Pad's keypad. This is accomplished by pressing MORE >
PREF > 7178 >, and pressing the NEXT or PREV button until the Programmable mode is
indicated, and pressing ENTER.

Type Mismatch Error

Ensure that the Smart Pad is not set for serial dump mode (only versions under 501). To
do this, navigate the Smart Pad in the following sequence: MORE > PREF > [CODE] >
CONF > COM > STOP. If the error persists, cycle power to the unit and restart the
SmartLog software.

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PGC Inc. SmartLog Version 3.0.7 January, 2013

Error Opening A File

39042.660810 *Comment containing unit-specific
data such as serial number, software version, tuning
Open the log file in a text browser (such as values and other information. *
Microsoft Word Pad) and determine whether
its format has been corrupted. The log file is Time AP RP WP AO WS WO
39042.660810 21.71 49.86 15.18 035.2 15.04 034.8
comprised of a Header Comment line
39042.660845 21.71 49.86 15.18 035.2 15.04 034.8
including the serial number, Smart Pad 39042.660868 *Changed air set point to 25 deg C*
software version number, tuning values and 39042.660868 21.72 49.89 15.23 035.6 15.04 033.4
other important information. Comment 39042.660891 21.71 49.86 15.18 035.2 15.04 034.8
format, including the Header Comment and
any note left using shift+right click, includes
the “*” sign, text comment, including carriage returns/line feeds, terminated with the “*”
sign. The logged data lines consist of an encoded time followed by the six logged
variables. The integer value of the time code stands for how many days since 1/1/1900
and the decimal portion is the current time divided by 24 hours. If the file has been
corrupted, correct it manually, save the file and try to open it again.

Can’t Change Water Set Point or Rh Set Point

Check the selected control mode. Cascade mode does not allow the user to change the
water set point and Two-Temperature mode does not allow the user to change Rh set
point. The set points and tuning screens have those fields grayed out and disabled to
remind the user that those set points may not be altered. Otherwise make sure SmartLog
is still connected. Click on the “Connect” label at the bottom left corner of the screen and
the command line box should become visible. If there are commands and no replies then
the connection has been lost (see above for checking connection).

Can’t Send E-mails

See the section in this manual entitled Testing E-mail Functionality to test e-mail
functions without having to wait for log files to auto-generate or for an alarm to trip.

Make sure the appropriate check boxes are checked beside the desired recipients. If
when attempting to send an e-mail you receive an error message that reads “The attempt
to connect timed out,” you likely have chosen the incorrect IP address for the SMTP
server. Contact your IT technician or internet service provider to make sure you have the
correct numerical address. Check the recipient addresses for errors. If one recipient
receives an e-mail and another does not, the error is likely on the receiving end, but this
can also happen if the SMTP address is incorrect.

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NOTES

Parameter Generation and Control, Inc.

P. O. Box 129 1054 Old US 70 West Black Mountain, NC 28711
Phone: (800) 438-5494 Fax: (828) 669-6928
International Phone: (828) 699-8717
technical@humiditycontrol.com