Lightning Batch Automation Controls

Lightning is RexCon’s newest batching control system, offering improvements on the successful RexCon Control and Communication Center (RC3). The Lightning control platform is based on a new state-of-the-art PLC with high speed Ethernet communications for an extremely fast batching control. This PLC also allows for easy firmware updates and data backups via USB port.

The PLC, I/O modules, power supply, and I/O relays are all DIN rail mounted to simplify maintenance and expansion. These parts are available around the world, so replacements are readily available quickly.

Both the Windows PC-based operator interface and manual panel for Lightning are intentionally kept the same as the RC3 control which users are already familiar with.

Lightning Features:

• PLC & PC software update from a USB drive
• Uses an off-the-shelf power supply
• Components use standard DIN rail mounting
• Same look and feel as the RC3 so operations are familiar to existing users
• In the wall-mount j-box, all parts are off-the-shelf
• PLC CPU module is much faster than the RC3

• Up to 5 scales
• Up to 20 total bins
• Up to 20 total bins
• Up to 20 liquid meters
• Up to 3 mixers

• PC Software Operates Under Windows 10™, 7™ and future versions.
• All Data Files are in Industry Standard Microsoft Access Database Format (*.mdb)
• RC³ Backup Utility Saves All Data Files onto a USB Flash Drive
• Real-Time Color Graphics Displays Progress of Each Product as it is Batched
• Easy to Operate, Quick and Easy to Train Operators to Batch
• Complete Management and Reporting of the Batching Process
• On-Hand Inventory of all Products Including Entry and tracking of Received Products
• U.S. or Metric Units Completely Supported Including Automatic Conversion
• Display/Print in English, Spanish, or other Available Languages
• Rexcon Service Techs can remotely login to the RC3 to Provide Updates, Diagnose Issues, and modify Configuration Settings
• Remote Batching is supported
• Open Licensing – No software restrictions on the number of PC locations
• Non-Proprietary Electrical / Hardware Components available worldwide

• Any Windows compatible printer can be used including a wireless printer
• Easy setup of two printers for tickets and/or reports
• Electronic tickets can be can be saved in a folder and automatically sent as an email
• Reprint Complete Ticket of any Archived Batch
• No Limit on Number of Archived Batches
• No Limit on Number of Products, Formulas, Customers, Drivers, Trucks or Jobs
• Product, Formula, Customer, Driver, Truck or Job Names up to 20 Alpha-Numeric Characters
• Tracking/Reporting of Truck Usage
• Tracking/Reporting of Mixer(s) Usage
• Tracking/Reporting of Product Usage by Job, Customer, or Mix

• Operator-Configurable Water Holdback
• Easily blend two waters (for example hot & cold water)
• Full support of manual entry of aggregate moistures when a bin moisture probe is not used
• Full support of moisture probe Dynamic Moisture Compensation of each batch
• Moisture Probe in Each Agg Bin is supported
• Manual Batch Tracking and Ticket Printing
• Multi-Batch Operation Allows the Operator to Specify a Batch Size Greater than the Size of Scales, Mixer or Truck, RC3 will Batch 2 or 3 loads and Print a Single Ticket
• Bin Mapping of Aggregate and Cement Bins to their Associated Scales
• Automatic Scale Discharge Rate Control Including a Configurable Modifier for Each Truck
• Admixture Percent Modifier that can be changed on the Batch Start Window
• Up to 3 Admixtures can be added to any Batch on the Batch Start Window
• (Optional) PC Display of Plant Air Pressure Includes Warning
• Low Level Product On-hand Inventory Warning
• Switch Bin on a Product No-Flow during the Batching Process
• Calculation and Display of the Water/Cement Ratio on the Batch Start Window
• Batch View Automatically Updates Water/Cement Ratio Display as Temper Water is Added to Mixer
• Full Support of Ice Additions Manually, Semi-Auto, or Fully Automatic
• Onscreen Digital Slump that accurately displays and saves mixer slump data

• Desktop manual panel and wall-mount panel (contains PLC and plant interface)
• Includes Central Mix Control – Slump Meter, Mix Timer, and Temper Water Button
• Cables to connect PC with peripherals and with the manual panel
• If Desired, Bulk-head connectors on RC3 to interface to the plant control cords
• Cables to connect the batching computer with the load cell meters
• (Optional) Support of Dual Displays
• Supports Multiple Printers over Parallel, USB, Ethernet, or Wireless
• Interface to Real Time (Optional) Silo Level Hardware with Visual Graphics
• Interface to Dispatch Software / Accounting with (Optional) “Host Computer Interface” (ULink)
• Interface to Dispatch Software with (Optional) “Host Computer Interface” (ULink)
• Interface to FiveCubits via Truck Load Event
• Interface to (Optional) Truck “Call Board” Display
• Interface two RC3 controls to share common inventory (e.g. bins, silos, etc.)
• Remote batching
• Remote diagnostics and Updates
• E-mail electronic tickets
• Multiple moisture probes
• Multiple language support
• 1 year “Platinum Plan” support (free phone support & free software updates during RexCon business hours)

• PLC & PC software update from a USB drive
• Uses an off-the-shelf power supply
• Components use standard DIN rail mounting
• Same look and feel as the RC3 so operations are familiar to existing users
• In the wall-mount j-box, all parts are off-the-shelf
• PLC CPU module is much faster than the RC3

All the features supported by RC3 are also supported by the Lightning control.