ICP DAS USA Cleanroom Leak Detection & Access Control Solution
Introduction
A leading semiconductor manufacturer specializing in thick-film substrates and custom semiconductor packaging required a reliable way to monitor and control cleanroom environmental conditions. Its products are used in image sensors, optoelectronic components, solar cells, and other high-tech applications, making strict control of temperature, humidity, and cleanliness essential.
As part of the manufacturing process, clean water is used to wash semiconductor chip fragments after dicing. Occasional water leaks on the cleanroom floor could halt equipment and production lines, resulting in costly downtime. Previously, leak detection relied on manual inspections by management personnel, reducing operational efficiency and delaying response times.
The company evaluated other monitoring systems, but many required complex controller and sensor configurations, programming expertise, and lacked real-time alarm capabilities. These limitations made them difficult to maintain and operate.
To address these challenges, the customer sought a complete environmental monitoring solution that could:
ICP DAS USA’s cleanroom environmental monitoring solution delivered an integrated, easy-to-manage system that met all of these requirements.
ICP DAS USA Cleanroom Environmental Monitoring Solution
Combines three key components:
Working together with the WISE-5231 IIoT Edge Controller, these devices collect and transmit leak detection, temperature, humidity, and access control data to a central control center for real-time remote monitoring and management.
The resulting solution helps maintain strict cleanroom environmental standards, reduces response times to critical events, improves operational efficiency, and minimizes the risk of equipment damage and production downtime.
How the Solution Works
The iSN-101/S2/DIN Liquid Leak Detection Module, which combines the iSN-101 I/O Module and CA-LLD-DC100X-L030 leak detection cable, continuously monitors for water leaks. When a leak is detected, the iSN-101 sends the event data to the WISE-5231 IIoT Edge Controller via Modbus RTU for immediate processing and response.
The DL-100TM485P Temperature & Humidity Data Logger measures environmental conditions within the cleanroom and transmits temperature and humidity data to the WISE-5231 through Modbus RTU, enabling real-time environmental monitoring.
For access control, the tM-PD3R3 Digital Input and Relay Module collects access data from entry terminals and forwards it to the WISE-5231 via Modbus RTU. When an employee is successfully authenticated, the controller unlocks the door. If access is denied, the system immediately notifies management personnel with an alarm.
Centralized Monitoring and Automated Response
ICP DAS USA’s WISE IIoT Edge Controllers provide a powerful platform for industrial monitoring and control applications. With built-in IF-THEN-ELSE logic, they can execute automation tasks reliably without additional programming software. The controllers also support scheduling, mathematical functions, and email notifications for enhanced system management.
In this application, the WISE-5231 serves as the central controller, collecting leak detection, temperature, humidity, and access control data and transmitting it to the control center via Modbus TCP. When abnormal conditions are detected, such as a water leak, environmental threshold violation, or unauthorized access attempt, the controller automatically triggers alarms and predefined response actions, helping personnel respond quickly and maintain a safe, efficient cleanroom environment.
Benefits of ICP DAS USA’s Cleanroom Environmental Monitoring Solution
ICP DAS USA’s WISE IIoT Edge Controllers feature an intuitive web-based interface that allows users to configure control logic without programming. Control workflows can be created and adjusted directly through the HMI, reducing setup time and simplifying ongoing management.
The WISE Series IIoT Edge Controllers include built-in data logging and recovery functions, helping ensure critical environmental data is retained and protected even during communication disruptions or unexpected events.
ICP DAS USA’s modules and controllers support the industry-standard Modbus RTU protocol, making it simple to integrate leak detection, environmental monitoring, and access control devices into existing automation systems.
The iSN-101/S2/DIN Liquid Leak Detection Module and tM-PD3R3 Digital Input & Relay Module feature a built-in dual watchdog mechanism. This functionality helps maintain reliable communication between the host controller and I/O modules. If communication is interrupted, preconfigured safe values can be applied automatically to support safe system operation.
ICP DAS USA Intelligent Environmental Monitoring Solution 2.0
Advanced Leak Detection and Alarm System
For enhanced protection, customers can add the ALM-Horn-BR Sound and Light Alarm Module and iKAN Industrial LED Displays within the cleanroom environment.
When the iSN-101 Liquid Leak Detection Module detects a leak, it immediately activates the ALM-Horn-BR, triggering both audible and visual alarms to alert nearby personnel. At the same time, the WISE IIoT Edge Controller sends real-time alarm information to the iKAN LED Display, providing clear notification of the event and helping personnel respond quickly.
The iKAN Series Industrial LED Displays support both ASCII and Unicode character sets, enabling multilingual message display. With Modbus communication support, they can be easily integrated into PLC, HMI, and SCADA systems for a wide range of industrial monitoring and automation applications.
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ICP DAS USA’s temperature and humidity monitoring solution combines real-time environmental monitoring with automated climate control. When temperatures rise above preset limits, the WISE IIoT Edge Controller can automatically activate air conditioning through the IR-712-MTCP module, while current conditions are displayed on an iKAN LED display for immediate operator awareness.
ICP DAS USA’s access control monitoring solution combines intelligent automation with video surveillance. When unauthorized access is detected, the WISE IIoT Edge Controller automatically activates the iCAM-ZMR8422X IP camera, captures real-time images, and sends alerts to management via email or LINE, helping ensure fast response and improved facility security.
Conclusion
By deploying ICP DAS USA’s environmental monitoring solution, the customer gained real-time visibility into critical cleanroom conditions while improving safety, efficiency, and response times. The integrated system enables proactive monitoring of leaks, environmental conditions, and facility access, helping ensure reliable production and supporting long-term smart factory initiatives.
