PLC Controller & HMI for Leak Testing Automation

Product Specifications

Technical details and manufacturing context for PLC Controller & HMI

Definition

This product is a combined PLC (Programmable Logic Controller) and HMI (Human-Machine Interface) system designed as the central control unit within a Leak Testing Module. It executes test sequences, monitors sensor inputs, controls actuators, and provides an operator interface for test configuration and results display. The PLC runs programmed logic to manage the leak testing process, while the HMI offers a visual interface for operators to monitor status, set parameters, and view results. Input signals from pressure sensors, flow meters, and position sensors are processed by the PLC, which then outputs control signals to valves, pumps, and other actuators to perform precise leak testing cycles. The system is housed in a plastic enclosure with metal mounting brackets and contains electronic components. Key parameters include a supply voltage of 24 V DC ±10% (per IEC 61131-2), power consumption of 15–60 W depending on I/O configuration, and an operating/storage temperature range of -40 to 85 °C (per IEC 60068-2-1/2). Relative humidity range is 10–95% non-condensing (per IEC 60068-2-78). Ingress protection is IP54–IP65 for panel-mounted HMI (per IEC 60529). Analog input resolution is 12–16 bits, digital I/O count is 16–32, and communication interfaces include Ethernet/IP, Profinet, and Modbus TCP (per IEC 61158). The HMI screen size ranges from 7 to 15 inches with resolutions from 800×480 to 1920×1080 pixels. Weight is 2–5 kg, and dimensions vary from 200×150×60 to 400×300×100 mm (W×H×D). All values are reference ranges and must be verified for the specific model and application with the legal manufacturer or supplier.

Working Principle

The PLC executes a stored program to sequence the leak testing process. It reads analog and digital inputs from sensors (pressure, flow, position) and compares them against setpoints. Based on the logic, it activates outputs to control valves, pumps, and actuators. The HMI communicates with the PLC to display real-time data, allow parameter changes, and show test results. The system operates in cycles, including pressurization, stabilization, measurement, and venting, with the PLC ensuring timing and safety interlocks.

Common Materials

Electronic components, Plastic housing, Metal mounting brackets

Technical Parameters

Parameter	Typical range	Notes & selection driver
Operating Pressure	1.0–1.6 MPa
Supply Voltage	24 ±10% V DC	Wide-range input for industrial stabilityIEC 61131-2
Power Consumption	15–60 W	Depends on I/O configuration
Operating Temperature	-40–85 °C	Extended range for harsh environmentsIEC 60068-2-1/2
Storage Temperature	-40–85 °C	Same as operating rangeIEC 60068-2-1/2
Relative Humidity	10–95 % RH	Non-condensingIEC 60068-2-78
Ingress Protection	IP54–IP65	For panel-mounted HMIIEC 60529
Analog Input Resolution	12–16 bit	Higher resolution for precise leak testing
Digital I/O Count	16–32	Configurable inputs/outputs
Communication Interface	1–2	Ethernet/IP, Profinet, Modbus TCPIEC 61158
HMI Screen Size	7–15 inch	TFT color display
HMI Resolution	800×480–1920×1080 pixels	Higher resolution for detailed graphics
Weight	2–5 kg	Depending on configuration
Dimensions (W×H×D)	200×150×60–400×300×100 mm	Panel cutout varies

Ranges are indicative industry figures for RFQ preparation, not a supplier commitment. Confirm every value and standard with the legal manufacturer before ordering.

Components / BOM

PLC CPU Module
Executes control logic and processes I/O signals

Material: Electronic components, plastic housing
HMI Touch Screen
Provides visual interface and operator input

Material: Glass, plastic, electronic components
Communication Module
Enables data exchange with other devices and systems

Material: Electronic components, plastic housing
Power Supply Unit
Provides regulated power to all components

Material: Electronic components, metal housing

Applied To / Applications

This component is essential for the following industrial systems and equipment:

Leak Testing Module

View system integration details

Manufacturers of PLC Controller & HMI

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Frequently Asked Questions

What communication protocols are supported?

The system supports Ethernet/IP, Profinet, and Modbus TCP, with 1–2 interfaces, per IEC 61158. Confirm protocol availability and configuration with the supplier.

What are the environmental limits for operation?

Operating and storage temperature range is -40 to 85 °C (per IEC 60068-2-1/2). Relative humidity is 10–95% non-condensing (per IEC 60068-2-78). Ingress protection is IP54–IP65 for panel-mounted HMI (per IEC 60529). Always verify these limits for your installation.

How many digital I/O points are available?

The digital I/O count is 16–32, configurable. The exact number depends on the configuration. Check the technical datasheet for your specific model.

Data Basis

Editorial classification, named public sources where available, and source-reviewed manufacturer records.

Preliminary Technical Classification

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pressure:	0 to 10 bar (sensor input range), 0 to 100 bar (system control capability)
flow rate:	0.1 to 100 L/min (leak test flow range)
temperature:	0°C to 50°C (operating), -20°C to 70°C (storage)
slurry concentration:	Up to 20% solids by volume (for compatible media)

PLC Controller & HMI

Product Specifications

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