Programmable Logic Relays Outperform Analogic/Mechanical Controls

Flexicon controls utilize programmable logic relays (PLRs) instead of hard relays, reducing the cost, size and potential failure associated with mechanical controls, while adding digital programmability to even the most basic Flexicon equipment.

Essentially PLCs in miniature, PLRs replace physical relay logic with digital programmable logic, offering a range of significant advantages over mechanical controls including:

  • Multi-function capability:
    A single PLR can perform numerous functions such as counting, sequencing, timing and real-time clock operations, expanding the capabilities of Flexicon equipment without increasing the cost or complexity of its controls.
  • Programmability:
    Logic can be modified quickly and easily since there is no need to add or replace components such as physical relays and timers. Based on feedback from existing level sensors or upstream/downstream equipment for example, the PLR's timing program can be fine tuned to start, stop, slow, speed-up, delay, advance or cycle equipment functions according to individual processes and material characteristics. No physical modifications to the panel may be necessary, even if additional sensors or other signals are added to the process. In many cases, reprogramming the PLR is as simple as setting a thermostat, and can be accomplished by an operator having little or no expertise.
  • Field serviceability:
    PLRs simplify troubleshooting by plant personnel, and allow emailing of programs to and from the Flexicon Controls Department for troubleshooting, reinstallation and/or customization of programs.
  • Lower component and assembly costs:
    Since the PLR replaces numerous components, the overall number of electrical components is lower, reducing assembly costs as well as material costs in many cases.
  • Reduced number and size of panels:
    One PLR can replace numerous electrical components, significantly reducing panel size requirements. Due to its number of inputs and outputs, a single PLR can also consolidate controls from multiple pieces of equipment such as flow promotion devices, dust collectors and conveyors, eliminating the need for sub panels while streamlining installation of the system.
  • Increased reliability and decreased parts inventory:
    PLRs eliminate the potential failure and maintenance associated with hard relays, timers and other components, and eliminate the need to stock these individual components. Should a PLR fail, an operator can replace it, download the program, and resume operation with minimal downtime.
Programmable Logic Relays

One PLR (foreground) can eliminate the need for multiple components, increasing programmability and reliability, while reducing initial cost and maintenance.