Optimized Control Panel for Fogger Systems
Integrating Advanced Control Technologies in
Fogger Applications
A building's humidity levels are influenced by ventilation, indoor temperature, and external environmental factors. For instance, at 10°C in the winter, the outdoor relative humidity (RH) may be 80%. The RH can decrease to 30% when this air is heated to 40°C inside, which is frequently too low for many processes. Controlling humidity is, therefore, crucial in many businesses.
In industrial environments, humidifiers are employed to keep humidity levels steady. They accomplish this by releasing water droplets into the air, maintaining the ideal humidity level inside a closed space.
To develop and install a humidifier (fogger) control panel to stabilise the air's humidity level. This includes monitoring the relative humidity in the environment and spraying water droplets into the air to maintain the RH value at the required level.
Requirements Analysis
Initial Assessment:
The textile industry requires a specific humidity level in the room to keep the threads moist. If the humidity level falls below a threshold, increased stress on the threads could lead to their breaking.
A humidifier prevents this by maintaining a steady humidity level in the space. When the humidity level falls, the humidifier is activated to return it to the desired level.
Key Requirements:
- Precise control of humidity levels in the room
- Accurate humidity sensing and feedback
- Different modes of operation and safety features
Solution Design
Libratherm Product Selection
- Temperature & Humidity Controller/Indicator
(DTH-966-C)
DTH-966-C has two analogue inputs for displaying temperature and Relative Humidity. It accepts (4-20)mADC input from the temperature and humidity sensor and gives a proportional output of (4-20)mADC to the VFD. This instrument is used to indicate temperature and control relative humidity. It operates on a 230VAC Supply.
- Programmable Cyclic Timer
(DTR-721)
Digital Cyclic timer model DTR-721 is designed using a high-speed microcontroller for accurate and reliable functions. This timer can control time-dependent events, such as starting or stopping the water pump at a set interval. DTR-721 can be used as an ON-DELAY, OFF-DELAY, or CYCLIC-MODE of operations.
- Temperature & Humidity Sensor
The Temperature / Humidity Transmitter converts temperature and humidity input from the sensor to a corresponding (4-20)mA output. Its output will be given as input to DTH-966-C.
Design Consideration
- Terminal block for field connections
Terminal blocks are used in the control panel for field connections to keep the wiring organised and neat and provide secure and insulated connection points for wires, preventing short circuits and ensuring safe operation.
- Isolation Transformer
The Isolation Transformer with Delay Timer provides a 415VAC to 230VAC isolated supply with a (0-10) second adjustable delay timer. This is used to power the controllers.
- Auto-OFF-Manual Switch
The Auto-OFF-Manual switch allows you to set the humidifier control panel to Auto, Timer, or Manual mode.
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Auto Mode: In auto mode, Relative Humidity is controlled through DTH-966-C, and the control output of DTH-966-C is given to the VFD. When the actual humidity is below the set point, the pump starts. Switching the pump on and off will accurately control the humidity of the environment.
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OFF Mode: In the timer mode, the pump will operate through DTR-721. It will remain ON as per the Set time (tON) and OFF as per the Set time (tOFF).
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Manual Mode: In this mode, the pump will directly turn ON.
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Variable Frequency Drive (VFD)
The variable frequency drive is a device used to control an electric motor's speed and torque by changing its power supply's frequency and voltage. In this panel, the VFD helps control the speed of the motor, which maintains the pressure at which water is sprayed in the atmosphere.
System Architecture
Closed Loop System
The humidifier control panel includes a T+Rh sensor, a DTH-966-C controller, and a variable-frequency drive (VFD). The T+Rh sensor monitors the room's humidity. The water pumps remain off until the room's relative humidity (RH) reaches or exceeds the controller's set point.
When the room's humidity falls below the set point, the sensor signals the DTH-966-C controller. The controller then sends a control output to the VFD, which adjusts the water pump's speed based on the humidity drop. The water pumps activate, sprinkling water in the room. The sprinklers stay on until the RH level matches the controller's set point.
Benefits
- Providing Ideal Production Environments
In order to preserve product quality and avoid problems like fibre breakage in the textile industry, the control panel precisely regulates humidity levels.
- Reduced Production Time
Regular humidity control can accelerate production cycles and increase efficiency by speeding up manufacturing operations.
- Preserving the Appropriate Humidity Levels
Stable humidity is maintained by the system, preventing spoiling and flaws in delicate sectors like electronics and pharmaceuticals.
- Static Electricity Mitigation
Appropriate humidity levels promote safety, protect equipment, and lessen the chance of static electricity accumulation.
Key Takeaways
A reliable and effective method of controlling humidity levels in industrial environments, including textile manufacturing, is the humidifier control panel. It meets a variety of client needs by providing precise control and flexibility through the use of cutting-edge technologies. Significant operational and financial benefits result from this system's increased energy efficiency, decreased downtime, and improved product quality.
- Summary
By automating humidity control, this system maintains consistent ambient conditions that improve output quality and efficiency. Because of its adaptable attributes, it may be used for a wide range of industrial applications, including HVAC, dust suppression, fogging systems for greenhouses, irrigation systems, and many more. As a result, it provides a flexible way to maintain proper moisture levels.
- Future Prospects
The need for sophisticated systems like this humidifier control panel is expected to rise as the necessity for efficient environmental control expands across sectors. Its accuracy and versatility make it a viable option for use in the future, and it has the potential to become a standard in a number of industrial domains.
The control panel implemented by Libratherm for Humidifier offers a proven, customizable, and efficient option for businesses in the textile industry. Please contact Libratherm for more information or a consultation. Our team of experts is ready to assist in designing and implementing a control panel tailored to your specific needs, ensuring optimal performance and quality in your operations.
