Industrial Wireless 3 Channel Production Counter Datasheet

Vladislav Yordanov

Device Overview
Probes Specifications
Probe Configuration and Wiring
Power Requirements and Expected Battery Life
- Power Requirements
- Expected Battery Life

Explore the 3 Channel Production Counter Capabilities

Device Overview

The 3 Channel Production Counter is a device specifically designed to track production counts and machine uptime events in industrial settings. It is a flexible device that can be configured to observe one or more events via different input types – break beam sensor, photo eye sensor, reflector sensor, dry contact closure, and wet contact closure.

It has long range wireless capabilities utilizing robust Mesh networking protocols with high level of security and network reliability. It is compact, durable, and powered by long-lasting batteries.

Features

Industrial Grade Production Count Monitoring
Measure Production Uptime
Measure Number of Cycles
Dry Contact Closure Input
Wet Contact Closure Input
Beam Break and Photo Eye Sensor Input-Based Event Detection
Encrypted Communication with 2 Mile Wireless Range
Operating Temperature Range -40 to +85 °C
Humidity Range 0–90%
Wall-Mounted or Magnet Mounted IP65 Rated Enclosure
For Indoor and Outdoor Use
Many Gateway and Modem Options Available

Status LED

The Status LED is used to indicate errors or other sensor diagnostics.

LED blinks once – Message was sent successfully and no error in last sensor read as well in data transmission.

LED blinks twice and then one more time – Message was sent successfully but there was an error in last sensor read.

LED blinks thrice – MCU is having issue communicating with the radio module.

Sensor Specifications

Specifications	Minimum	Nominal	Maximum	Notes
Width		3.54"
Length		4.52"
Height		2.16"
Enclosure Rating				IP65, NEMA 1,2,4,4X,12,13, UL-508
Temperature Rating	-40° C	23° C	85° C	Component Rating
Tested Temperature	0° C	23° C	40° C	As Tested by NCD Staff
Probe Operating Temperature	-40° C	23° C	85° C	As Tested by NCD Staff
Inputs				Digital, Acceleration, Magnetic, Current
Opto-input Voltage	3.3 V		24V
Reporting interval	5 seconds	600 seconds	16777215 seconds	How often data is transmitted wirelessly
Range of counter values	1		4294967295	The maximum number of events the sensor can count to
CT Current	1.5% FS		FS	Minimum current read by the CT. CT range 100 to 1000Amp

Printed Circuit Board Specifications

Parameter	Minimum	Nominal	Maximum	Notes
Trace Width	0.007 inch	0.012 inch	0.25 inch	Trace Width depends on the Trace Type
Layer Count		2L - Rigid		Top and Bottom Layer
Material Type	FR-4 TG170	FR-4 TG170	FR-4 TG180
Surface Finish		ENIG 2u"
IPC Standard		IPC CLASS 2
Finished Copper Foil		1.0/1.0 OZ
Finished Thickness		0.062 inc
Fine line <4.0/4.0mil		No
Blind & Burried Vias		No
Non-Conductive Resin		No
Conductive Resin		No

Mechanical Drawing

RF Module Specifications

Parameter	868MHz	900MHz	2.4GHz
Frequency Band	863 MHz to 870 MHz	902 to 928 MHz	ISM 2.4 GHz
Transmitter Power	Up to 13 dBm ERP	Up to 24 dBm	Up to 8 dBm
Receiver Sensitivity	-106 dBm at 80 Kbps	-101 dBm at 200 Kbps	-103 dBm at 250 Kbps
Range (dense urban)	~1000ft	~1000ft	~300ft
Range (line of sight)	~2 miles	~2 miles	~1 mile
Data Rate	80 Kbps	200 Kbps	250 Kbps
Networking Protocol	Digi XBee® DigiMesh®	Digi XBee® DigiMesh®	Digi XBee® DigiMesh®
Encryption	128-bit AES	128-bit AES	128-bit
Reliable Packet Delivery	Retries/acknowledgements	Retries/acknowledgements	Retries/acknowledgements
IDs	PAN ID and addresses, cluster IDs and endpoints (optional)	PAN ID and addresses, cluster IDs and endpoints (optional)	PAN ID and addresses, cluster IDs and endpoints (optional)
Certification	CE/RED, ROHS Compliant	FCC (America), IC (Canada), C-Tick (Australia), Anatel (Brazil), IDA (Singapore)	FCC (America), IC (Canada), RCM (Australia), Anatel (Brazil), Teleck MIC (Japan), KCC (South Korea)

Probes Specifications

Digital Inputs

The Industrial Digital Input and Sensor Reader is a compact and robust device tailored to interpret signals from various digital inputs and sensors prevalent in industrial settings, including brake beam sensors, photo reflectors, photo eye sensors, and on/off signals. It can also work with counter with a digital pulse outputs to easily integrate with existing equipment in production lines or plants for example.

With high accuracy and reliability, it offers real-time data acquisition and monitoring, seamlessly integrating into existing industrial automation systems. Its user-friendly interface and flexible configuration options ensure easy setup and compatibility with diverse applications, enhancing operational efficiency, equipment reliability, and production optimization. Ideal for conveyor systems, packaging machinery, and robotic systems, it empowers industrial operators with streamlined data interpretation and control capabilities, minimizing downtime and maximizing productivity.

Note! When using the Photo Eye or Break Beam sensor you need to use external power as they are not powered via the batteries. Such use cases need to use the sensor where it can be powered by mains.

Note! When using a digital input sensor the Rising edge of the pulse is used for the cycle count by default, however you can configure it to be a falling edge instead (via software configuration of the sensor).

Probe Configuration and Wiring

Warning! Make sure you wire you probe correctly as per the instruction below, otherwise you risk damaging the probe and/or the sensor.

Power Requirements and Expected Battery Life

Power Requirements

This device is Powered by a single D-cell (LR20) battery

Warning! This Device comes with a special Non-rechargeable battery. It is a special Hybrid battery that is a combination of a standard D-cell and a Supercapacitor in one package. Only replace with an equivalent Hybrid battery (a simple D-cell would not work).

Note! The device has auto failover, if you are using it with an external power supply (this can be selected via the switch), if the supply fails the device will utilize the battery as a power source. Thus, it will not interrupt its function, no data will be lost.

While changing the batteries:

Turn off the sensor
Only use a new D-cell battery (obtain one from NCD, as it has a built in supercapacitor, this is not a regular battery).
Make sure to align the connector in the proper orientation (this will assure you match the polarity)
The battery should not be replaced in fire-risky areas
Do NOT install a rechargeable battery

Expected Battery Life

Specifications	Nominal	Maximum	Notes
Batteries size	16000mAh		This device has a single D-Cell (LR20) battery
Battery Life 1 TPD		10 Years	TPD Transmissions per Day
Battery Life 12 TPD		8 Years	TPD Transmissions per Day
Battery Life 24 TPD		5 Year	TPD Transmissions per Day
Battery Life 96 TPD		3 Year	TPD Transmissions per Day

Note! The Truth About Battery Life Under the best of circumstances, the best non-rechargeable batteries commonly available today are limited to a 10 year non-working shelf life in a room temperature environment. Factors such as actual usage, temperature, and humidity will impact the working life. Be wary of any battery claims in excess of 10 years, as this would only apply to the most exotic and expensive batteries that are not commonly available. Also note that most battery chemistries are not rated for use in extreme temperatures. NCD only uses the best Non-Rechargeable Lithium batteries available today, which are also rated for use in extreme temperatures and have been tested by our customers in light radioactive environments. Lithium batteries offer a 10 year maximum expected shelf life due to limitations of battery technology. NCD will never rate sensor life beyond the rated shelf life of the best batteries available today, which is currently 10 years.

Store and Documentation

Head to the NCD store if you want to purchase the 3 Channel Production Counter.

If you already have the device and would like more information into its basic and advanced operations check out the Quick Start Guide and User Manual.

Industrial Wireless 3 Channel Production Counter Datasheet

Explore the 3 Channel Production Counter Capabilities