In 2024, as part of X-Fab Kuching's building expansion, they added a new Vacuum Pump Control Skid at their new facility. Ultech Engineering supported this initiative by supplying, installing and commissioning three Local Control Panels (LCPs) for the Vacuum Pump Control Skid, and Starter Control Panel (SCP) provided by the main contractor. The scope also included cable laying and termination for the Pump Skid instrument. Additionally, Ultech Engineering provided provisions for end-user monitoring via end-user Distributed Control System (DCS), ensuring seamless integration into their expanded infrastructure.
A Vacuum Pump Control System regulates the operation of vacuum pumps to maintain desired vacuum levels in a sealed environment. It controls the pump's operation based on pressure readings, ensuring the process runs efficiently and within the required conditions. The system typically includes components like pressure sensors, controllers, valves, and the pump itself, and it can automatically adjust pump speed or operation to optimize energy use and performance. These systems are commonly used in manufacturing, laboratories, and HVAC industries.
In the semiconductor manufacturing industry, facilities like X-Fab Kuching, Sarawak specialise in creating chips that enhance people's lives and producing semiconductor devices that contribute to saving lives, connecting people, and enabling cleaner transportation. At X-Fab, it is all about the sleek, round wafers fabricated in cleanrooms across six global production facilities used in a wide range of applications, from consumer and mobile communications, automotive application and medical applications. At the heart of such operations lies the vacuum control system, which is critical in enabling precise and contamination-free manufacturing processes.
At X-Fab Kuching, vacuum pump control systems are indispensable for achieving high precision and reliability in semiconductor production. They ensure that the critical vacuum conditions for processes such as etching, deposition, and implantation are consistently maintained. By enhancing process stability, improving efficiency, and supporting sustainability, these systems are pivotal in enabling companies like X-Fab to deliver semiconductor solutions globally.
The X-Fab Vacuum Pump Control System project focuses on supporting the vacuum pump operations at X-Fab’s expanded facility in Kuching, Sarawak. Ultech Engineering began by creating the drawing layouts in November 2023 and started building the panels in April 2024, providing a new integrated control solution to enhance vacuum pump efficiency and reliability.
This project serves the semiconductor manufacturing industry, specifically X-Fab Kuching, known for its precise wafer fabrication processes. To maintain product quality and yield, strict control over parameters like vacuum levels is essential. As part of its facility expansion, X-Fab is installing a new vacuum pump skid on the extended side and Ultech Engineering supported this by supplying, installing, and commissioning three Local Control Panels (LCPs) for the vacuum pump control skid, along with the Starter Control Panel (SCP) provided by the main contractor. The vacuum pump control skid is a modular, pre-assembled unit that combines the vacuum pump, control system, and related components such as piping, valves, and sensors on a single platform, ensuring easier installation and operation.
Led by Project Automation Manager Mr. Wang Zhi Xian and Automation and Control Engineer Mr. Mike Gaby Law Ik Pin from Ultech Engineering, this project aims to supply, install, and commission three Local Control Panels, as well as cable laying and termination for all associated instruments that aligns with the end user's control philosophy and serves as the control system for the vacuum pump skid.
The Local Control Panel (LCP) will seamlessly interface with three Starter Control Panels (SCPs) provided by the main contractor, ensuring optimal integration and enhanced control. The three local control panels will be connected or integrated with the three starter control panels in such a way that they can communicate and work together. For instance, the local control panel may have manual controls that send signals to the starter control panels to start or stop the motors, or they could receive feedback from the starter control panels about the motor's status. Additionally, provisions are being made to enable the end user to monitor system performance through their Distributed Control System (DCS).
A vacuum control skid (which combines a vacuum pump, control system and other components like piping, valves and sensors on a single platform) benefits from installing a Local Control Panel because it acts as a control system for the vacuum pump by enabling:
Furthermore, in the Local Control Panel (LCP), Ultech Engineering has implemented Siemens' technology to further optimize performance and precision.
The project leverages Siemens’ CPU 1510SP-1 PN and associated Siemens components such as circuit protection and controller, power supply and SIMATIC modules and accessories. Besides that, in this project, some relays, terminal blocks and other accessories from our brand partner Weidmuller have been used as well. These technologies are pivotal for achieving the automation and precision required in vacuum pump operations.
The Siemens CPU 1510SP-1 PN is a compact CPU designed specifically for the SIMATIC ET 200SP distributed I/O system. While referred to as a “CPU” in its product name, it functions as a fully capable PLC because it includes all the necessary components for automation such as the processing unit, I/O interfaces, communication interface and memory. It is based on the S7-1500 CPU 1511-1 PN and offers high-performance control for medium-level industrial automation tasks.
The CPU enables high system and machine availability and supports integration with up to 64 IO devices via PROFINET IO. It offers advanced communication options, including PROFINET I-Device, shared I-Device for up to four controllers, and the PROFINET IO IRT interface. Additionally, it includes motion control functionalities for speed control and synchronization, making it versatile for industrial applications.
The CPU 1510SP-1 PN offers high-speed command processing and robust communication capabilities through its integrated PROFINET IO IRT interface. Its motion control functionalities support positioning, speed control, and synchronization, while its trace functions provide real-time diagnostics and error detection. The CPU supports isochronous mode synchronized data processing and program execution. Isochronous mode is a communication method used in digital systems, particularly in networks and control systems, where data is transmitted at regular, time-synchronized intervals. This ensures that operations requiring precise timing, such as real-time applications, maintain consistent performance, minimizing latency and optimizing system reliability.
Security features include password-based know-how protection, copy protection linked to the SIMATIC Memory Card, and a 4-stage authorization concept to prevent unauthorized access. Integrated system diagnostics in the TIA Portal and web server simplify fault detection and troubleshooting.
TIA Portal stands for Total Integrated Automation Portal. It is a software suite developed by Siemens for programming and configuring industrial automation systems. The TIA Portal provides a unified environment for working with various Siemens automation hardware, such as PLCs, HMIs and drives, allowing engineers to design, program, and manage the entire automation system from a single platform. Siemens TIA Portal exemplifies modern industrial automation through key aspects:
Together, these features make TIA Portal a cornerstone of efficient, flexible, and data-driven industrial automation. Ultech Engineering is already utilizing the TIA Portal in its operations and continues to push forward in maximizing its potential to enhance daily workflows and achieve greater innovation.
The SIMATIC ET 200SP is a modular and scalable distributed I/O system with IP20 protection. It is designed for compact enclosures and can communicate with SIMATIC controllers via PROFINET IP or PROFIBUS DP. Its compact design, ease of use, and high performance make it ideal for industrial automation. The system offers comprehensive diagnostics with plain text messages for rapid fault identification and resolution.
The ET 200SP supports up to 64 I/O modules per station, with options for digital, analogue, and speciality I/O. The system allows hot swapping, enabling module replacement without system downtime. Diagnostics are channel-specific and provide clear messages to facilitate maintenance. The compact design maximizes space efficiency, while integrated shielding ensures reliable communication in demanding industrial automation.
The synergy between Siemens CPU 1510SP-1 PN and SIMATIC ET 200SP provides a robust and scalable solution for X-Fab’s vacuum pump control system, ensuring real-time precision, high availability, and efficient performance. Siemens CPU 1510SP-1 PN acts as the central processing unit, efficiently handling data processing and communication with the SIMATIC ET 200SP’s distributed I/O modules. This integrated approach maximizes the operational efficiency of the vacuum pumps, enhances diagnostic capabilities, and ensures that X-Fab's semiconductor manufacturing process remains uninterrupted and highly reliable.
While it is not strictly required to use the Siemens CPU 1510SP-1 PN and the SIMATIC ET 200SP together, doing so offers a range of benefits that optimize performance, scalability, and reliability, making this combination the ideal choice for controlling vacuum pumps in semiconductor production. The advanced communication via PROFINET, modular scalability, diagnostics, enhanced system security, and motion control features of the integrated system provide a highly efficient and future-proof solution, ensuring operational excellence for X-Fab in the long term.
A power supply is an essential component of most electronic systems and devices, responsible for converting electrical energy from one form to another. Its primary role is to provide the necessary power for operation while maintaining a stable and reliable voltage to the connected equipment. In simple terms, a power supply takes the input power (either alternating current, AC, or direct current, DC) and converts it to a specific output voltage and current required by the equipment. It can also regulate power to ensure safe operation by protecting against overcurrent, overvoltage, or overheating.
The Siemens SITOP PSU100S is a single-phase power supply designed for industrial applications where reliable 24 V DC power is needed. The SITOP PSU100S is part of Siemens' SITOP (SITOP stands for Siemens Top Power Supply) family of power supplies, which are engineered to provide continuous, stable, and efficient power to critical systems in industries like automation, control, and process industries.
The Siemens SITOP PSU100S power supply provides several key advantages that directly enhance the X-Fab Vacuum Pump Control System project:
The Factory Acceptance Testing (FAT) for the X-FAB Vacuum Pump Control Panel ensured system readiness for delivery and installation. Preliminary inspections verified mechanical construction, visual appearance, assembly items, workmanship, and wiring. Grounding tests checked earth bonding and instrument ground continuity to prevent faults. During system testing, power-on verification, push button and switch functionality, and PLC operations were validated. Functionality tests on three panels covered start, stop, fault, and alarm sequences, along with Modbus communication checks.
Finally, shock tests and system restart tests ensured operational stability. The project completed the Factory Acceptance Testing on 6th August 2024, which the client was satisfied with, and the Local Control Panels have been delivered to Kuching. However, site installation is pending as the facility is not yet ready for equipment installation. Once the site is prepared, the panels will undergo Site Acceptance Testing (SAT) and commissioning.
Mr. Mike Gaby Law Ik Pin, one of Ultech Engineering's Automation Engineers involved in the X-Fab project, stated that there have been no challenges up to the phase of Factory Acceptance Testing. However, challenges may arise during the commissioning phase.
After implementing the new solutions provided by Ultech Engineering, X-Fab will experience several significant benefits.
The X-Fab Vacuum Pump Control System project exemplifies Ultech Engineering’s dedication to delivering innovative, high-performance automation solutions. By leveraging Siemens’ technology and aligning the system’s design with X-Fab's operational objectives, the project is poised to enhance production efficiency, reliability, and scalability. As the site nears readiness, the successful deployment of this system will mark a pivotal milestone for Ultech Engineering and X-Fab's ongoing pursuit of operational excellence and industry leadership.
This collaboration highlights how modern automation technologies can drive efficiency and precision in semiconductor manufacturing. By implementing Siemens' advanced CPU 1510SP-1 PN, SIMATIC ET 200SP, and SITOP PSU100S, the project delivers a state-of-the-art control solution that enhances operational reliability, minimizes downtime, and optimizes production processes. As the project moves toward its commissioning phase, Ultech Engineering continues to demonstrate its expertise in delivering tailored solutions that meet the exacting demands of the semiconductor industry.
