Editorial Technical Reference

PLC Controller & HMI

This page explains how PLC Controller & HMI is classified within Machinery and Equipment Manufacturing. Technical values and manufacturer relationships are research references; confirm the current specification and supplier evidence for each order.

Technical Definition & Core Assembly

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.

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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
ParameterTypical rangeNotes & selection driver
Operating Pressure1.0–1.6 MPa
Supply Voltage24 ±10% V DCWide-range input for industrial stabilityIEC 61131-2
Power Consumption15–60 WDepends on I/O configuration
Operating Temperature-40–85 °CExtended range for harsh environmentsIEC 60068-2-1/2
Storage Temperature-40–85 °CSame as operating rangeIEC 60068-2-1/2
Relative Humidity10–95 % RHNon-condensingIEC 60068-2-78
Ingress ProtectionIP54–IP65For panel-mounted HMIIEC 60529
Analog Input Resolution12–16 bitHigher resolution for precise leak testing
Digital I/O Count16–32Configurable inputs/outputs
Communication Interface1–2Ethernet/IP, Profinet, Modbus TCPIEC 61158
HMI Screen Size7–15 inchTFT color display
HMI Resolution800×480–1920×1080 pixelsHigher resolution for detailed graphics
Weight2–5 kgDepending on configuration
Dimensions (W×H×D)200×150×60–400×300×100 mmPanel 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

Application & selection

Application Fit & Sizing Matrix

Operational Limits
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)
Media Compatibility
✓ Compressed air/dry gases ✓ Hydraulic fluids (mineral oil-based) ✓ Water/glycol mixtures
Unsuitable: Highly corrosive chemicals (e.g., concentrated acids, strong oxidizers)
Sizing Data Required
  • Maximum test pressure required (bar)
  • Required leak detection sensitivity (cc/min)
  • Number of test stations to be controlled

Risk, maintenance & compliance

Reliability & Engineering Risk Analysis

Failure Mode & Root Cause
Communication failure
Cause: Network cable damage, electromagnetic interference, or incorrect IP configuration disrupting data exchange between PLC and HMI.
Memory corruption
Cause: Power surges, improper shutdowns, or firmware bugs leading to loss of program logic or HMI screen data.
Maintenance Indicators
  • HMI screen freezing or displaying 'Communication Error' messages
  • PLC status LEDs showing abnormal patterns (e.g., constant red/flashing)
Engineering Tips
  • Implement regular backups of PLC programs and HMI configurations, storing them off-site with version control.
  • Install uninterruptible power supplies (UPS) and surge protectors, and maintain proper grounding to prevent electrical damage.

Indicative industry ranges for design and RFQ preparation. Confirm the exact figures and applicable standard with the manufacturer before specifying.

Compliance & Manufacturing Standards

Applicable Standards
ISO 13849-1: Safety of machinery - Safety-related parts of control systems ANSI/ISA-95.00.01: Enterprise-Control System Integration CE Marking (EU Directive 2014/35/EU for Low Voltage Equipment)

Quoted from the published standard.

Manufacturing Precision
  • Enclosure IP Rating: IP65 (dust-tight and protected against water jets)
  • Electrical Connection Tightening Torque: +/-10% of specified value
Quality Inspection
  • Functional Safety Test (verification of safety functions per ISO 13849)
  • Environmental Stress Screening (temperature cycling and vibration testing)
Technical documentation
Request current drawings, revision history, and a signed specification sheet.
Manufacturing capability
Verify equipment lists, process limits, capacity, and representative production evidence.
Inspection readiness
Confirm test methods, calibrated equipment, sampling plans, and traceable reports.
Supplier transparency
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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. See the editorial policy.

Related equipment

Applied To / Applications

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

Leak Testing Module
View system integration details

Industrial Ecosystem & Supply Chain Structure

Data Basis

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

Preliminary Technical Classification
This page supports structured research, RFQ preparation, and supplier evaluation. It does not replace buyer-led supplier qualification, standards review, or technical approval.

Compiled and source-reviewed by the CNFX editorial team. Each manufacturer above links to the page on that company's own website where the product is listed, with the date we checked it. How we source and review · Page last updated 12 October 2026

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