Commercial Metal Company has reached out to DC-DC-Digital for a method of keeping count of steel bars in storage. The DC-152N-C Steel Bar Production Counter is a custom-built network-enabled counting solution designed specifically for steel production facilities that need a reliable way to track material movement during loading and unloading operations. This counter provides real-time visibility into production or inventory counts, helping operators maintain accurate material tracking across shipping, receiving, and storage areas.

In a typical steel production workflow, the customer powers the unit and begins operating the counter either through physical input devices or via the network-based web interface. The system is designed to be highly flexible, allowing operators to increment, decrement, or reset counts based on how materials move through the facility. Whether steel bars are being loaded for shipment or unloaded into storage, the DC-152N-C ensures the displayed count remains accurate and synchronized across all control points.

The counter operates as a true network counter, meaning it can be controlled locally through plug-and-play dry contact wiring or remotely through the integrated web page interface. The close contact wires are housed in a junction box located on the left side of the enclosure, making installation and access straightforward. Each wire is clearly labeled for its function, allowing quick setup with minimal configuration.

Manual operation through the wiring is achieved using a dry momentary contact between the selected function wire and the common wire. This design allows the counter to integrate seamlessly with the customer’s existing input devices, such as buttons, switches, or sensors. When the increment wire is momentarily connected to common, the count increases by one. When the decrement wire is used, the count decreases accordingly. A dedicated reset wire instantly returns the displayed value to zero. Any change made through the physical wiring is immediately reflected on the network web page, ensuring consistent visibility.

In addition to physical inputs, the DC-152N-C can be fully controlled through its network web page. From a keyboard or connected workstation, operators can increment or decrement the count with a single click, reset the display to zero, or manually set a specific value. For example, if 99 steel bars have been unloaded into storage or staged for shipping, the operator can simply enter “99” and apply the value, instantly updating the display. This capability is especially useful for correcting counts, performing audits, or initializing values at the start of a shift.

Key functional capabilities of the DC-152N-C include:

• Network-based manual counting through a web page interface
• Increment, decrement, and reset control via dry contact wiring
• Real-time synchronization between physical inputs and network display
• Manual value entry for inventory or shipment verification

From a hardware standpoint, the DC-152N-C is built to withstand demanding industrial environments. The unit is housed in an extruded aluminum enclosure rated IP66 for outdoor wet locations. The black powder-coated finish is both tough and fingerprint-resistant, making it suitable for production floors and exterior installations. The 15-inch display is highly visible and can be read from distances of up to 750 feet, ensuring clear visibility across large steel facilities.

Additional hardware and system details include:

• Two-digit display capable of counting from 0 to 99
• 120 VAC power via junction box with pigtails
• Strut channel mounting for secure installation on concrete walls
• Ethernet-connected network web page via an IOT expansion card
• Plug-and-play close contact wires for custom input devices

The Ethernet connection for the network interface is located in a separate junction box on the top right side of the enclosure, keeping wiring organized and protected. With both network and hardwired control options available, the DC-152N-C gives customers the freedom to use their own input devices and tailor the system to their specific steel production processes.

Overall, the DC-152N-C Steel Bar Production Counter provides a robust, flexible, and easy-to-operate solution for accurately tracking material counts in steel manufacturing, shipping, and receiving operations.

See similar product: DC-152C-W-IN

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