Capabilities & Customization
One module, configured to your line
The FLEX-5 is software-defined. Point it at your PLC, load your own sounds, drop in your own report template, and drive every function from a clean set of PLC bits — all without installing anything on your HMI or PC.
Built-in Web UI
Configure everything from a browser
The FLEX-5 serves its own configuration interface on :8080. No vendor software, no license, no install — just open the device's address.
- ✓Set the device IP and PLC IP with live connection feedback
- ✓Scan, pair and manage up to 3 Bluetooth devices (with passkey)
- ✓Monitor USB status and browse the on-device data archive
- ✓Download any CSV / Excel file, or copy selected files to USB
- ✓Restart or factory-reset the device in one click
Status auto-refreshes every 5 seconds. Interface shown is representative.
Change IP Address:
Current IP: 192.168.1.199
Change PLC Address:
PLC IP Status: Connected
| Tera Scanner 8100 | DC:0D:30:1A:2B:3C |
| Honeywell Voyager | 00:1B:DC:0F:11:22 |
| File | Size | Modified |
|---|---|---|
| 20260606-094312_Run_A.csv | 18 KB | 09:43 |
| 20260606-094312_Run_A.xlsx | 42 KB | 09:43 |
What you can customize
Configurable options
The FLEX-5 adapts to your process rather than the other way around. These are the options you control.
Network & connectivity
Point the FLEX-5 at any PLC and network from the built-in web UI.
- ▹Device IP address
- Set a static IP from the browser — written to the device network config.
- ▹PLC IP address
- Target any Allen Bradley PLC; live connection-status feedback.
- ▹Bluetooth devices
- Scan and pair up to 3 devices, with optional passkey/PIN; remove anytime.
Audio & sound
Load your own sound library and trigger any file from the PLC.
- ▹Custom sound library
- Up to 250 of your own MP3 / WAV files, selected by index from the PLC.
- ▹Environment sound
- Real-time ambient monitoring (44.1 kHz) reported back to the PLC as an RMS level.
Reporting & data logging
Make the report yours — drop in a template and map fields to PLC tags.
- ▹Excel report template
- Swap in your own .xlsx; the FLEX-5 fills the highlighted cells automatically.
- ▹Field → PLC tag mapping
- Header metadata and per-row columns map to your own PLC tag names.
- ▹Data array sizing
- Store-config tags set how many string / real / integer values are captured per record.
- ▹Archive retention
- Tune how many files and days of history the device keeps (default 30 / 30).
- ▹Batch size
- Up to 42 part records per batch report.
Under the hood
Software & connectivity
- PLC protocol
- EtherNet/IP (Allen Bradley ControlLogix, CompactLogix, Micro800)
- Configuration UI
- Built-in web interface on port 8080, auto-refresh every 5 s
- Audio
- Up to 250 custom MP3 / WAV files, PLC-selectable
- Data export
- CSV + auto-populated Excel (.xlsx) report per batch
- Scanning
- USB and Bluetooth barcode scanners (incl. intrinsically safe)
- Networking
- Static IP for device and PLC, set from the browser
- On-device archive
- Last 30 files / 30 days of CSV and XLSX, downloadable
For integrators
The Control_DINT command map
Every FLEX-5 function is driven by a single 20-element FLEX.Control_DINT[] array. Your PLC sets a bit, the FLEX-5 performs the action and clears it — a clean, predictable handshake.
| Bit | Function |
|---|---|
| DINT[0] | Select sound file (1–250) |
| DINT[1] | “Sound playing” indicator (FLEX → PLC) |
| DINT[2] | Append current part data to the active batch (CSV + Excel) |
| DINT[3] | Push serial.csv to the PLC |
| DINT[4] | Enable / disable environment-sound capture |
| DINT[5] | Heartbeat / watchdog (toggles every second) |
| DINT[6] | Refresh the audio file list from the PLC |
| DINT[7] | “Barcode scanning active” indicator |
| DINT[8] | Start scanner (1) / start Bluetooth stream (2) |
| DINT[9] | Play selected sound |
| DINT[10] | “Bluetooth stream active” indicator |
| DINT[11] | Retrieve newest 30 archived files to USB |
| DINT[12] | USB fault indicator (0 = OK, 1 = fault) |
| DINT[13] | Start a new work-order batch (uses FLEX.File_Name) |
| DINT[14] | Finalize batch + mirror CSV / XLSX to USB |
| DINT[15] | USB presence check |
| DINT[16–19] | Reserved for future use |
Full tag reference and store-config details are in the user guide.
Have a use case in mind?
Tell us about your line and we'll help you map the FLEX-5 to it.