HollySys LE Compact PLC Hardware with 20 Module IO System

The HollySys LE Compact PLC hardware ecosystem delivers robust, highly scalable automation control for single-machine units and compact production lines. Featuring integrated functional expansion boards and support for up to 20 I/O modules, this versatile controller ensures seamless execution in harsh industrial environments.

Industrial automation engineers frequently encounter space constraints, harsh thermal fluctuations, and communication bottlenecks in compact machine building. The HollySys LE compact controller series resolves these deployment challenges through a flexible modular architecture and native multi-machine interconnectivity over serial and Ethernet ports without complex programming overhead. Powered by specialized CPU variations including the LE5104, LE5105, LE5107E, LE5108, LE5118, LE5119, LE5107L, and LE5109L, this hardware line accommodates diverse digital and analog configurations. Integrated features such as high-speed hardware counters up to 400 kHz, rapid pulse capture down to 10 μs, and immediate output channels ensure precise real-time motion and logic control. Operating reliably across wide temperature thresholds, the hardware mitigates external electromagnetic interference through robust galvanic isolation and terminal block separation, safeguarding continuous plant floor uptime.

Technical Specifications

CPU Model: LE5104

CPU Type: Standard @ 24 VDC

Integrated Digital Inputs: 8 Points @ 24 VDC

Integrated Digital Outputs: 6 Points @ Transistor

Integrated Analog Inputs: 0 Points @ Standard

Integrated Analog Outputs: 0 Points @ Standard

Expandable I/O Modules: 10 Modules @ Max Capacity

Optional Function Expansion Board: Not Supported @ CPU Body

High-Speed Counter: 1-Phase 20 kHz @ Single Channel

High-Speed Counter Range: -231 to 231 - 1 @ 32-bit Integer

High-Speed Output: 2 Channels @ 20 kHz

Pulse Capture: 2 Channels @ 10 μs

Fast External Interrupt: 2 Channels @ 10 μs

Immediate Output: 6 Channels @ Terminal Block

Program Upload Support: Supported @ Software Level

Force Function Support: Supported @ Diagnostic Mode

Real-Time Clock: Built-In Clock @ ±3 minutes / month

Program Storage Capacity: 64 KB @ Flash Memory

Input Area: 1 KB @ Memory Map

Output Area: 1 KB @ Memory Map

Intermediate Area: 4 KB @ Internal Storage

Random Area: 9 KB @ Data Memory

Special Register Area: 1 KB @ System Reserved

Power-Down Retentive Area: 2 KB @ Battery-Backed RAM

Execution Speed Bit Instruction: 0.1 μs @ Boolean Logic

Communication Interface: 1 Port @ RS485

Communication Protocol: Modbus Master/Slave @ Free Port Mode

Input Power Supply Voltage: 24 VDC @ Rated Input

Output Power Supply Voltage: 24 VDC @ Load Circuit

Dimensions W x H x D: 78 x 97 x 90 mm @ DIN Rail Mount

System Integration and Hardware Setup

Physical installation of the HollySys LE compact controller requires mounting on standard 35 mm DIN rails within a properly grounded metallic enclosure to suppress electrical noise. Field wiring should utilize shielded twisted-pair cables for all RS485 serial loops and analog signal lines, terminating the shield drain wire to the nearest earth grounding bar to prevent ground loops. Power distribution to the 24 VDC or 220 VAC terminals must incorporate external fast-acting fuses or circuit breakers to protect against downstream short circuits. Removable terminal blocks simplify pre-wiring and replacement procedures during maintenance windows without disturbing field wire harnesses. Multi-machine interlinking can be established directly through physical terminal connections, enabling synchronized data exchange between adjacent controllers without requiring custom PLC communication code.

Reliability and Environmental Durability

Engineered for deployment in demanding industrial spaces, the LE hardware series complies with strict industrial electromagnetic compatibility standards. Wide temperature operational readiness allows the controllers to function reliably in unconditioned cabinets subject to ambient thermal shifts. Natural convection cooling is optimized through distinct ventilation slots on the molded housing, eliminating the need for failure-prone external cooling fans. Non-volatile flash memory and battery-backed RAM protect user logic and retentive data registers against unexpected power interruptions. Component selection focuses on high Mean Time Between Failures metrics, ensuring long-term operational stability for continuous manufacturing processes.

Selection Guidance and Alternative Options

Selecting the appropriate LE controller variant depends directly on the required digital-to-analog ratio, expansion slot capacity, and communication interface demands of the target machine. For basic discrete logic applications, models such as the LE5104 or LE5105 provide cost-effective fixed I/O counts with basic high-speed counting. Applications demanding extensive motion control, high-density transistor outputs, or dual RS485 and RJ45 ports benefit from advanced variants like the LE5118 or LE5108. Beijing Zhongping Technology maintains a comprehensive inventory of these original automation components, offering expert technical consultation and cross-reference selection support to ensure seamless integration into existing architectures.

Frequently Asked Questions (FAQ)

1. What are the standard lead times and shipping policies for ordering the HollySys LE controller? Orders processed through Beijing Zhongping Technology are typically dispatched from local stock within 24 to 48 hours, subject to order volume and destination logistics.

2. What warranty coverage is provided with the purchase of this hardware? All units are backed by a comprehensive 12-month standard industrial warranty covering manufacturing defects and hardware malfunctions.

3. Can the LE CPU module support analog expansion cards if the base model lacks native analog channels? Yes, CPU models supporting expansion boards accept snap-on option modules to scale up analog input and output capabilities.

4. How is multi-machine communication established without programming? The system supports native multi-machine interconnectivity protocols directly through designated terminal ports for peer data exchange.

5. What programming software is required to configure the LE series? The controllers are programmed using HollySys proprietary engineering software suites designed for the LE compact architecture.

6. Are the terminal blocks removable for easier wiring replacement? Yes, the hardware incorporates pluggable terminal blocks to facilitate fast wiring disconnects during maintenance cycles.

7. What is the maximum number of I/O modules that can be attached to a single CPU? Depending on the specific model variant, the system supports up to 20 total expansion modules.

8. Does the real-time clock require an external battery replacement? The built-in real-time clock relies on internal backup circuitry to maintain timekeeping accuracy during short-term power losses.