How to Calibrate Humidity and Temperature Sensor in Trend IQE3 Xcite Controller

How to Calibrate Honeywell Trend IQE3 Xcite Temperature & Humidity Sensors (Step-by-Step Guide with pictures)

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Introduction

Maintaining accurate temperature and humidity control is critical in textile humidification plants. Even a small deviation in sensor readings can affect product quality, efficiency, and energy consumption.
In systems using the Honeywell Trend IQE3 Xcite Controller, sensors continuously monitor environmental conditions and send data to the controller for precise control. However, over time, these sensors may drift and start showing incorrect values.
This guide will walk you through a simple, professional step-by-step method to calibrate humidity and temperature sensors, ensuring your system operates with maximum accuracy and reliability.

Why Sensor Calibration is Important?

In a textile humidification plant, automation systems play a critical role in maintaining proper humidity and temperature across all departments, including spinning, preparatory, Autoconer and weaving.
Maintaining proper humidity and temperature is essential for:

Yarn strength
Yarn quality
Static control
Process stability
Energy efficiency

When a new humidification automation system is installed in any department, humidity and temperature sensors are placed at appropriate locations. These sensors continuously measure environmental conditions and send signals to the DDC (Direct Digital Controller).
The controller then displays real-time values on the HMI or SCADA system for monitoring and control.
During new installations, sensors typically do not require calibration. However, after one or two years of operation, periodic calibration is recommended to ensure accuracy.
For calibration, you can use a manual measuring device such as a whirling hygrometer.
Take multiple readings (around 10 to 15) using the manual instrument and compare them with the sensor readings.

Take multiple readings using the manual instrument and compare them with the sensor readings

If, in most cases (about 7 to 8 out of 10 readings), the sensor shows a deviation of 5 to 10 value in humidity or temperature, it indicates that calibration is required. In such cases, an offset adjustment should be applied to the sensor values.
The acceptable difference between the manual instrument and the sensor reading should be within ±2.5 value.

Before performing calibration, it is recommended to read the guide:

How to Calculate Humidity and Temperature in a Humidification Plant Using Hygrometers (Step-by-Step Guide)

Calibration Process

After recording a minimum of 10 readings from the hygrometer or whirling hygrometer and the department sensor, determine and finalize the required humidity or temperature calibration value.

Carefully follow the step-by-step procedure below to accurately calibrate the humidity and temperature sensor values.

Step 1: Access the Controller

First, identify the IP address of your Trend IQE3 Xcite controller.
Open a web browser such as Google Chrome, Mozilla Firefox or Microsoft Edge.
In the address bar, enter the controller’s IP address (for example, 192.168.1.10) and press Enter.

If the controller page does not open, verify that the controller is properly connected to your PC and that network communication is established.
Ensure the signal and IP configuration are correct. If needed, refer to the guide on how to check whether the controller is online.
Once the connection is confirmed, continue with the sensor calibration process.
If all the above steps are correct, the controller interface will load in your browser. It will display the controller variant as IQE3 Xcite, as shown in the reference image.

continue with the sensor calibration process

Step 2: Navigate to Sensor Settings

Next, click the modules option below on the web browser.
After click the Modules option on the left side your controller all option will be displayed, and find the sensors option.

Modules option on the left side your controller

Click the Sensors option,
If your controller shows multiple department sensors like (Spinning, Autoconer, preparatory) it will denoted in the Label section or simply denotes Rh and Temp, then choose your department/plant humidity or temperature sensor values.

Item – Displays the parameter settings of the programmed sensors.
Label – Displays the name of the programmed sensor.
Value – Displays the current or live sensor reading.
Units – Displays the SI units of the programmed sensor values.
Graph – Displays the recorded trend data of the programmed sensors.
Alarm – Displays high, low, and out-of-limit alarm conditions of the sensor values.

Displays the parameter settings of the programmed sensors

Step 3: Apply Calibration (Offset)

Select the sensor you want to calibrate and click on the corresponding item.
For example, I choose the S8 RH sensor.
The current value of the S8 sensor is 60.31% RH.
Click on the S8 sensor to open the sensor settings dialog box.
In the settings window, locate the Offset option.
Enter the required calibration value (positive or negative) in the offset field.
For example, enter +5 as the offset value.
After entering the value, scroll down and click the tick (✓) symbol to save the settings.

Enter the required calibration value in the offset field

A confirmation message will appear indicating that the value has been successfully written.
Close the settings window.
Return to the sensor page and refresh it.
The updated calibration value will now be reflected in the S8 RH sensor reading.
Now the current S8 RH sensor reading is 64.93% RH.

Repeat the same procedure for other sensors as required.

Important Notes⚠️

Do not modify any other parameter values in the S8 sensor parameter settings.
Changing other parameters may affect sensor performance or result in incorrect readings.

Changing other parameters may affect sensor performance

After completing the calibration, refresh the sensor page and confirm that the offset value has been updated correctly.
Avoid applying large calibration adjustments.
The offset should be limited to a maximum range of ±10.
Once calibration is completed, the next calibration should typically be performed after 3 to 6 months.
Frequent calibration (such as weekly adjustments with large positive or negative values) is not recommended. If such frequent corrections are required, inspect the sensor condition or verify the controller functionality.
This calibration procedure is also applicable to the Honeywell Trend IQ4E controller.

For better understanding, refer to the related demonstration video: watch here

Maintenance and Testing

Over time, dust may accumulate on the sensing element. Clean the sensing element only by using low compressed air or dry cloth.
Do not use water or cleaning agents on the sensing elements under any circumstances, as this may damage the sensor.

It is recommended to verify the sensor accuracy every 12 months.
If the sensor value is continuously fluctuating, check the sensor input and output voltage or current according to the sensor type.
Inspect the sensor power supply and control signal cables for any loose connections or physical damage.
If two sensors are installed in the department, move the faulty Sensor-1 to the working Sensor-2 location and check its operation. If Sensor-1 still does not function properly, replace it with a new sensor of the correct type and model suitable for the controller.

Conclusion

Accurate sensor calibration plays a vital role in maintaining stable humidity and temperature conditions in textile humidification systems. By following this step-by-step process, you can ensure reliable sensor performance, improved product quality, and efficient system operation.

Regular monitoring and proper calibration not only extend sensor life but also prevent costly process variations.

If you face any issues during calibration, feel free to reach out or leave a comment for assistance.

Engineering Perspective (E-E-A-T)

From an engineering maintenance perspective, periodic sensor calibration is considered a preventive maintenance practice rather than a corrective activity.
Environmental conditions such as dust accumulation, aging of sensing elements, airflow variation, and electrical noise can gradually affect sensor accuracy over time.
Performing regular verification using calibrated reference instruments like a hygrometer or whirling hygrometer helps maintain process consistency and operational efficiency.
Applying excessive offset values without proper validation is not recommended, as it may mask actual sensor or controller faults.
If repeated calibration adjustments are required within short intervals, engineers should inspect sensor placement, wiring integrity, power supply stability, and possible environmental interference before replacing the device.

Frequently Asked Questions (FAQs)

1. What happens if a humidity sensor is installed near an air outlet or water spray area?

A: Improper sensor placement can cause unstable or incorrect readings due to direct airflow, moisture exposure, or temperature variation. Sensors should always be installed in representative environmental locations for accurate monitoring.

2. Can incorrect sensor calibration affect textile production quality?

A: Yes. Incorrect humidity or temperature readings can lead to yarn breakage, increased static electricity, uneven moisture levels, and reduced product quality in textile manufacturing processes.

3. How can I identify whether the issue is with the sensor or the controller input?

A: You can verify this by connecting a known working sensor to the same controller input. If the new sensor displays correct values, the original sensor is faulty. If the problem remains, inspect the controller input configuration, wiring, or power supply.

About the Author – Insight Control System

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