Application Case of DC FFU Group Control Technology

1. Energy saving and efficient: DC motors themselves are more energy-efficient than AC motors. The group control system can automatically adjust the FFU speed according to actual cleaning needs (such as real-time particle counting and pressure difference signals), avoiding constant full speed operation and saving up to 30% -50% energy.
2. Accurate control: It can achieve stable and uniform pressure difference and wind speed in various areas of the workshop, which is the key to maintaining the airflow organization and cleanliness level of the clean room.
3. Centralized monitoring: Through the central control platform, the real-time monitoring of the operating status (speed, current, alarm, etc.) of each FFU greatly reduces the workload of operation and maintenance personnel.
4. High reliability: equipped with functions such as fault alarm and redundant backup. A single FFU failure will not affect the overall operation of the system, and the system can automatically adjust the surrounding FFU parameters to compensate for the air volume.
5. Simplified wiring: Communication methods such as RS-485, CAN bus, or Ethernet are usually used, which are simpler and have stronger anti-interference ability compared to traditional AC control wiring.

Industry: Semiconductor Integrated Circuit Manufacturing
1. Application scenario: Wafer processing area and lithography area of Class 1-100
2. Challenges and Needs:
2.1 The cleanliness requirements are extremely high (ISO grades 1-3), with almost strict particle control.
2.2 Production equipment generates a large amount of heat and requires stable airflow for heat dissipation and dust removal.
2.3 The process area is complex, and strict pressure gradients need to be maintained between each functional area to prevent cross contamination.
2.4 Energy consumption is extremely high, and electricity bills are the main part of operating costs.
Any downtime or fluctuations can cause significant economic losses.
Group control solution:
1. System architecture: Adopting a distributed control+central management model. Every few dozen FFUs are managed by a regional controller (PLC/dedicated controller), and all regional controllers are connected to the central monitoring computer (SCADA system) through industrial Ethernet.
2. Control strategy:
2.1 Fixed static pressure difference control: Static pressure sensors are installed in the return or exhaust ducts, and the group control system automatically adjusts the total speed of the FFU in the entire area based on the set static pressure value to maintain stable airflow.
2.2 Constant wind speed control: Set a fixed wind speed for the FFU directly above the key process platform to ensure high cleanliness of the process point.
2.3 Differential pressure linkage control: It is linked with the differential pressure sensor in the room to dynamically adjust the supply air volume (FFU speed) or exhaust air volume, ensuring stable differential pressure between the room, corridor, and rooms of different levels.
3. Implementation effect:
3.1 The cleanliness stability meets the design requirements and satisfies the nanoscale process requirements for chip production.
3.2 Through intelligent speed regulation, the annual average speed is controlled at around 70%, which has a significant energy-saving effect compared to full speed operation.
3.3 has achieved 7x24 hour uninterrupted stable operation, with real-time alarm function that can quickly locate the fault point and shorten maintenance time.

Industry: Biopharmaceuticals, Aseptic Preparations
1. Application scenarios: aseptic filling line, aseptic API production area
2. Challenges and Needs:
2.1 It is not only necessary to control particles, but also to control microorganisms (bacteria, fungi).
2.2 It must comply with the requirements of GMP (Good Manufacturing Practice) regulations and have complete data traceability and verification functions.
During the production process, there are different operating modes (production mode, standby mode, disinfection mode) that require different environmental parameters.
Group control solution:
1. System architecture: Adopting a highly reliable and GMP compliant control system, all operation logs, alarm records, and parameter modification records are automatically saved and cannot be tampered with, and can be used for audit tracking.
2. The control strategy is multi-mode control:
2.1 Production mode: FFU operates at full speed or high speed to ensure wind speed and pressure difference in high-risk areas.
2.2 Standby mode: When there is no production activity, the system automatically reduces the FFU speed, maintains positive pressure but significantly reduces energy consumption.
2.3 Disinfection mode: After ozone or VHP fumigation, the "purge mode" can be activated, and the FFU runs at high speed to quickly eliminate residual gases.
2.4 Alarm Management: Alerts such as low wind speed, FFU failure, and abnormal pressure difference will be notified to management personnel through sound, light, text messages, and other means to ensure timely intervention.
3. Implementation effect:
3.1 Fully meet the strict requirements and documentation requirements of GMP for sterile production environments.
3.2 By switching modes, energy consumption is significantly reduced during non production periods.
3.3 Ensure environmental safety during drug production and reduce the risk of product contamination.

Industry: Display panel manufacturing
1. Application scenarios: Array, Cell, Module workshop
2. Challenges and Needs:
2.1 The clean room has a huge area (up to 100000 square meters) and a large number of FFUs (tens of thousands).
2.2 Production processes are sensitive to vibration and noise, especially precision equipment such as photolithography.
2.3 The height of the factory building is high, and the replacement and maintenance of FFUs is a huge project.
Group control solution:
1. System architecture: Using mature industrial bus technologies such as Profibus and Modbus to build large-scale networks. The system has powerful self diagnostic function, which can provide early warning of motor life and prompt preventive maintenance.
2. Control strategy:
2.1 Grouping and zoning control: Divide the huge workshop into multiple logical control areas for independent adjustment, improving system response speed and management flexibility.
2.2 Low speed uniformity control: Under the premise of meeting cleanliness requirements, the system can intelligently adjust all FFUs to a lower and uniform speed, thereby minimizing vibration and noise and contributing to energy conservation.
3. Implementation effect:
3.1 Successfully managed a large-scale FFU cluster and stabilized the production environment.
3.2 By optimizing the rotational speed, a low vibration and low-noise environment is provided for precision production processes.
The preventive maintenance function reduces the risk of sudden large-scale failures and ensures the continuity of production.

 Summary: DC FFU group control technology has evolved from an "optional function" to a standard configuration for high-end cleanrooms. Its application cases are generally concentrated in industries with extremely high requirements for environmental control, energy consumption, and production reliability.
Suggestion for selection: For newly built or renovated cleanroom projects with Class 1000 or above and an area exceeding 500 square meters, it is strongly recommended to use a DC FFU group control system. Although the initial investment is relatively high, the long-term returns it brings in terms of operating energy consumption, maintenance costs, and control accuracy can usually be recovered within 1-3 years.
I hope the above cases can help you fully understand the practical application of DC FFU group control technology. If you have any questions about specific industries or scenarios, please feel free to further explore, www.saf-airfilters.com