You can’t fix the bottleneck you can’t see. A wireless 3-channel production counter that tracks cycles, uptime and downtime on three isolated inputs, so every stop and slowdown shows up in the data.
Made in USATrue first-pass yield. Two channels tell you good against bad. The third separates what you fixed from what you threw away, and rework is where the labor cost actually hides.
Where the line loses it. A count at every step turns a shortfall into a location. You stop arguing about which station is the constraint and read it off the gaps between the three.
Which of the three is behind. One counter, one battery, and one mesh connection cover an entire cell, so comparing three supposedly identical machines takes no extra hardware and no extra mounting.
Planned time vs. lost time. Splitting stoppages into faults and changeovers is the difference between a machine that breaks and a schedule that churns, and they call for opposite fixes.
| Sensor | Metric | Value | Time |
|---|---|---|---|
| Press Room Counter | Ch 1 Blanking Count | 18420.00 | 8/24/2026, 2:32:07 PM |
| Press Room Counter | Ch 2 Forming Count | 15980.00 | 8/24/2026, 2:32:07 PM |
| Press Room Counter | Ch 3 Trim Count | 12340.00 | 8/24/2026, 2:32:07 PM |
| Press Room Counter | Ch 1 Uptime | 26280.00 sec | 8/24/2026, 2:32:07 PM |
| Press Room Counter | Ch 1 Input Status | 1.00 | 8/24/2026, 2:32:07 PM |
| Press Room Counter | Battery | 3.02 V | 8/24/2026, 2:32:07 PM |
| Name | Sensor | Metric | Cond. | Thresh. | Current | Status |
|---|---|---|---|---|---|---|
| Low Throughput | Line 1 | Cycle Rate | Below | 20.00 | 42.00 | OK |
| Shift Target | Line 1 | Shift Count | Below | 16,000 | 18,420 | OK |
| Line Stopped | Stamping Press | Idle Time | Above | 300 s | 612 s | TRIGGERED |
| Low Battery | Packaging | Battery V | Below | 2.80 V | 3.30 V | OK |
| Name | Triggers | Action | Status |
|---|---|---|---|
| Line Stopped Alert | Line Stopped (Stamping Press) MET | Email (trigger+clear) supervisor@plant.com | ACTIVE |
| Throughput Watch | Low Throughput (Line 1) | Email (on trigger) ops@plant.com | OK |
| Battery Notice | Low Battery (Packaging) | Email (trigger+clear) maintenance@plant.com | OK |
| Name | Type | Format | Schedule | Last Sent | Enabled |
|---|---|---|---|---|---|
| Shift Production Summary | Fleet Summary | Daily at 6:00 AM | 06/29/2026 | ON | |
| Downtime Digest | Alert Digest | CSV | Daily at 8:00 AM | 06/29/2026 | ON |
| Packaging Line Group | Sensor Group | PDF+CSV | Monday at 8:00 AM | 06/29/2026 | ON |
| Weekly Throughput Roll-Up | Fleet Summary | Monday at 7:00 AM | 06/22/2026 | ON | |
| Cycle Count Export | Custom SQL Query | CSV | Daily at 11:55 PM | 06/29/2026 | ON |
| Channels | 3 |
| Input Types | Digital pulse / contact closure |
| Sensor Compatibility | PNP/NPN optical, break-beam, photo eye, reflector, dry & wet contact closure |
| Reported Data | Cumulative count, uptime (seconds), input status, and RTC timestamp |
| Uptime Calculation | On-board 32-bit accumulator; total time the input is active, reported in seconds |
| Input Status | Live input state (ON / OFF) at the moment of transmission |
| Report Types | Regular (user-defined interval) or Interrupt (immediate on input state change, when enabled) |
| Real-Time Clock | On-board RTC timestamps every transmission; a configured shift-end time automatically resets count and uptime |
| Isolated Input Voltage | 3.3V to 24V |
| Counter Resolution | 32-bit per channel |
| Counter Range | 1 to 4,294,967,295 events per channel |
| Frequency Bands | 868 MHz / 900 MHz / 2.4 GHz |
| Band class | Sub-GHz (868 / 900 MHz) — sub-gigahertz radio travels farther and penetrates walls and equipment far better than higher-frequency Wi-Fi or Bluetooth |
| Protocol | Long-range wireless mesh |
| Range (line of sight) | Up to ~2 miles (868/900MHz); ~1 mile (2.4GHz) |
| Range (dense urban) | ~1000 ft (868/900MHz); ~300 ft (2.4GHz) |
| Data Rate | 80 Kbps (868MHz); 200 Kbps (900MHz); 250 Kbps (2.4GHz) |
| Encryption | 128-bit AES |
| Battery | D-cell with Supercap |
| Battery Life | Up to 5 years |
| Sensor Power | Powered sensors (photo eyes, proximity switches) require their own external power supply — the counter battery powers the counter only |
| External Power | Optional externally powered variant, with automatic failover to battery |
| Power Options | Battery only, or external power connector + battery |
| Dimensions | 3.54″ W × 4.52″ L × 2.16″ H |
| Enclosure Rating | IP65 (main enclosure only); NEMA 1,2,4,4X,12,13; UL-508 |
| Operating Temperature | -40°C to +85°C (component rated, as tested) |
| Humidity | 0–90% |
| Mounting | Wall-mount or magnet-mount |
| 868/900MHz Models | CE/RED, RoHS |
| 2.4GHz Models | FCC (US), IC (Canada), RCM (Australia), Anatel (Brazil), MIC (Japan), KCC (South Korea), RoHS |
| Part number | PR63-10A_PWR |
One input, one count. Wire a photo eye, proximity switch, or contact closure to the single channel and it counts every pulse, even while asleep. The right pick when you need the number off one machine, one line, or one press.
Two independent inputs on one battery and one radio. The pick when the number you actually manage is a comparison, good against reject, in against out, cycles against faults, measured on the same device at the same instant.
Three independent isolated inputs sharing one battery, one radio, and one mesh connection. Each channel counts its own machine or station, so one device covers a whole cell and gives you the comparison between them.
Every one of these needs three counts taken at the same instant. Each channel keeps its own 32-bit counter, so the three numbers arrive already lined up, never stitched together afterward.
One Cell, Three Machines
Good, Reject, and Rework
Infeed, Outfeed, and Stoppage
Three Stations of One Process
Cycles, Faults, and the Operator’s Call
Three Utility Meters, One Counter
Strokes, Parts, and Scrap
Cases, Layers, and Pallets
Three Lanes of One FillerNot every channel has to be in use on day one. Wire what you have now, and the two spare inputs are already mounted, powered, and on the network when the next machine or the next question shows up.
Detailed configuration, channel setup, and deployment reference.
Answers to the most common questions about wireless production counting and uptime monitoring.
Our engineers answer in public on the community forum, and the thread stays up for the next person with the same question.
Ask on the NCD Community Forum