Automation of water heaters in PlC-based water process trainer

Department of Electrical Engineering, Faculty of Vocational Studies, Universitas Negeri Surabaya, Surabaya, East Java, Indonesia.

^* Corresponding author: daengrahmatullah@unesa.ac.id

Published online: 22 December 2025

Abstract

Advances in industrial technology require workers who not only understand theory but are also able to apply technical skills directly. One of the challenges faced is how to align the learning process with industry needs, particularly in liquid heating systems commonly used across various sectors. This study offers a solution by designing the Water Process Control Trainer as a practical learning tool for automated heating systems based on PLC and HMI. The contribution of this research is to provide a learning tool that represents an industrial heating system on a laboratory scale, as well as supporting students’ technical understanding and practical skills in the field of process automation. The methods used include system planning, selection, and integration of components such as heaters, PT100 sensors, Haiwell PLCs, HMIs, Solenoid valve, and water boosters. Following this, assembly and testing were conducted to ensure the heating function operates according to the designed automatic program scenario. The results of this study indicate that the system can control the water filling process, heating to a specific temperature, and automatic water return according to the predetermined setpoint. The system can also be operated via the HMI interface, allowing users to monitor and adjust parameters easily. This trainer provides a realistic learning experience that closely mirrors industrial scenarios. In conclusion, the Water Process Control Trainer is an effective practical learning tool for understanding automated heating systems and contributes to enhancing graduates’ readiness to meet the demands of modern industry.