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No PLC programming. No cloud accounts. Wire two sensors, power on, and start comparing.
Put a sensor on each isolated input, good parts on one, rejects on the other, or infeed on one and outfeed on the other. Works with any PNP or NPN sensor at 3.3–24V.
Self-forming wireless mesh network on 868MHz / 900MHz / 2.4GHz. Up to 2-mile line-of-sight range on the 868/900MHz models, with multi-hop routing across your facility.
Receives both counts, uptime, and status, stores them locally, and serves dashboards in your browser. Forward to any MES, CMMS, or cloud via MQTT or Node-RED.
Atrium charts both channels together, so yield, scrap rate, and shrinkage read straight off the dashboard. Alerts fire when the gap between them moves the wrong way.
One channel gives you a number. Two channels give you the number that number is hiding, because the value you actually manage is almost always the difference between a pair.
Live yield. Scrap stops being a number somebody totals at the end of the week and becomes a rate you can watch move while the line is still running.
Shrinkage and work-in-process. When outfeed drifts below infeed, product is stuck, jammed, or gone, and you know it while there’s still time to walk the line.
Stops per thousand cycles. A reliability number that holds up across shifts and part numbers, because it’s normalized to how much the machine actually ran.
Which twin is falling behind. Two identical machines rarely run identically, and one counter covering both makes the comparison automatic instead of anecdotal.
The Atrium Gateway isn’t just a data receiver. It’s a complete industrial IoT platform with dashboards, alerts, reporting, and productivity monitoring built in. Open your browser and go.
Drag-and-drop widgets let you build custom monitoring views for any audience, operators on the floor, quality engineers, or front-office leadership. Overlay the two channels on a single graph and the ratio between them becomes the thing everyone watches.
| Sensor | Metric | Value | Time |
|---|---|---|---|
| Filler Line Counter | Ch 1 Good Count | 18420.00 | 8/24/2026, 2:32:07 PM |
| Filler Line Counter | Ch 2 Reject Count | 742.00 | 8/24/2026, 2:32:07 PM |
| Filler Line Counter | Ch 1 Uptime | 26280.00 sec | 8/24/2026, 2:32:07 PM |
| Filler Line Counter | Ch 1 Input Status | 1.00 | 8/24/2026, 2:32:07 PM |
| Filler Line Counter | Battery | 3.02 V | 8/24/2026, 2:32:07 PM |
In Atrium, Triggers are threshold conditions on a single sensor metric, they fire when a value crosses the line. Actions link one or more triggers to responses like email or relay control, and run when every trigger is met. With two channels you can watch throughput and quality at the same time, and catch the shift where output held steady while scrap quietly doubled.
| Name | Sensor | Metric | Cond. | Thresh. | Current | Status |
|---|---|---|---|---|---|---|
| Yield Below Target | Filler Line | Ch1 / Ch2 Yield | Below | 95.00 | 96.00 | OK |
| Reject Spike | Cap Line | Ch2 Rate | Above | 30.00 | 61.00 | TRIGGERED |
| Outfeed Gap | Palletizer | Ch1 − Ch2 | Above | 150 | 38 | OK |
| Low Battery | Press Cell | Battery V | Below | 2.80 V | 3.30 V | OK |
| Name | Triggers | Action | Status |
|---|---|---|---|
| Scrap Escalation | Reject Spike (Cap Line) MET | Email (trigger+clear) quality@plant.com | ACTIVE |
| Yield Watch | Yield Below Target (Filler Line) | Email (on trigger) ops@plant.com | OK |
| Battery Notice | Low Battery (Press Cell) | Email (trigger+clear) maintenance@plant.com | OK |
The Productivity Monitor app uses live production-count data to automatically detect when machines are running, idle, or stopped. With two channels on one counter, a single sensor can report utilization for a pair of machines side by side.
Schedule recurring reports delivered straight to stakeholders’ inboxes. Yield summaries, sensor group roll-ups, and alert digests, all generated automatically and emailed on your chosen cadence.
| Name | Type | Format | Schedule | Last Sent | Enabled |
|---|---|---|---|---|---|
| Shift Yield Summary | Fleet Summary | Daily at 6:00 AM | 08/18/2026 | ON | |
| Scrap Digest | Alert Digest | CSV | Daily at 8:00 AM | 08/18/2026 | ON |
| Filler & Capper Group | Sensor Group | PDF+CSV | Monday at 8:00 AM | 08/17/2026 | ON |
| Weekly Throughput Roll-Up | Fleet Summary | Monday at 7:00 AM | 08/17/2026 | ON | |
| Both-Channel Export | Custom SQL Query | CSV | Daily at 11:55 PM | 08/18/2026 | ON |
The App Center runs on the gateway itself, an app store on your own hardware with no cloud account and nothing to sign into somewhere else. Browse the catalog in your browser, install what the job needs in seconds, and update it in place. Your gateway starts as a lean core and grows only where your operation actually needs it.
Atrium works as a fully self-contained system, but when you need to integrate, Node-RED is built in and ready. Push data to cloud platforms, databases, or custom APIs, all configured through a visual flow editor.
Two 32-bit counts, on-board run time, and live input state arriving in one transmission on one timestamp, so the ratio between the pair is exact.
Each input keeps its own running total, so the two counts never blur together. Isolated inputs protect the electronics from electrical noise on the plant floor.
Because both counts arrive from the same counter on the same timestamp, the comparison between them is exact, no clock drift between two sensors to reconcile later.
Works with photo eyes, break-beam, reflector, and proximity sensors, plus dry and wet contact closures. Inputs accept 3.3–24V, and the two channels don’t have to be the same kind of sensor.
The counter tracks how long each input stays active and reports total run time in seconds with every transmission. No formula to build downstream, the machine’s run time arrives as a number.
Each transmission carries the state of every input at that exact moment, on or off, so a dashboard shows whether the machine is running right now. Enable interrupt reporting and the counter transmits the instant that state changes.
A real-time clock timestamps every transmission. Set a shift-end time and the counter zeroes its counts and uptime on its own, so each shift starts clean without anyone pressing anything.
| Channels | 2 |
| 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 |
| Configuration | CFG button on enclosure |
| 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 |
| Antenna | External antenna on SMA connector |
| 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 |
| Sleep Mode | Power-efficient sleep; counts while asleep, wakes/samples/transmits |
| Battery Reporting | Battery level included with every transmission |
| 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) |
| 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 | PR63-23B |
Every one of these runs the same counting engine, the same D-cell power, the same wireless mesh, and the same Atrium dashboard and alerts — and every channel counts to 4,294,967,295. The only question is how many things you need to count from one spot.
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 two counts taken at the same instant. Each channel keeps its own 32-bit counter, so the two numbers arrive already lined up, never stitched together afterward.
Good vs. Reject CountingYield and scrap rate stop being something reconstructed after the shift ends. Both counts land on one device, so the ratio between them is live while there is still time to act on it.
Infeed vs. OutfeedThe gap between what enters a line and what leaves it is work-in-process when the line is healthy and shrinkage when it isn’t. One counter measures both ends against the same clock.
Two Machines, One CounterA pair of presses, molders, or fillers standing side by side can share a single counter — one battery to change, one radio to commission, and one place to see which of the two is falling behind.
Cycles vs. FaultsA raw stop count punishes the machine that ran the most. Counting strokes alongside the stops normalizes it, so what you compare is stops per thousand cycles rather than stops per shift.
Bidirectional In/Out CountingTwo sensors facing opposite directions turn totes, carts, vehicles, or people into an in count and an out count, and the running difference between them is occupancy.
Paired Flow-Meter LoggingPulse-output meters at each end of a loop should agree. When the two totals stop agreeing, you have a leak or a loss to find, and you knew it before the bill showed up.
Impressions vs. Waste SheetsMakeready loss is usually estimated at the end of a job, which is another way of saying it is guessed. Counting good sheets against waste on the same device makes it a number per job instead.
Shots vs. Short ShotsA molding process drifts long before anyone calls it a problem. Counting shots against rejects and purges on one counter turns that drift into a rising ratio you can watch, not a bin you notice is full.
Strokes vs. Parts Off the DieOn a multi-out die, strokes and parts are not the same number, and the gap between them is what tells you a station has stopped producing. Tooling maintenance gets scheduled on real stroke count.
Only one count to take today? The 1-channel counter does that on its own. Need a third input for rework, a stoppage, or a whole cell? That is the 3-channel counter.
The math is simple. One purchase versus compounding monthly fees.
Answers to the most common questions about two-channel wireless production counting.
The IoT Wireless 2 Channel Production Counter from NCD counts events from two separate sensors and transmits both totals wirelessly to a gateway. Each isolated channel connects to a photo eye, proximity sensor, or contact closure and keeps its own running count, so you can measure two related things at once, such as good parts and rejects, without wiring back to a PLC.
Because the number most plants actually manage is a comparison rather than a raw total. Yield is good parts against rejects, shrinkage is infeed against outfeed, and reliability is faults against cycles. A single channel gives you one side of that; two channels on the same counter give you both sides on the same timestamp, so the ratio between them is exact.
Yes. The two inputs are independent, so one channel can read a photo eye while the other reads a proximity switch, a dry contact, or a flow meter’s pulse output. Both accept any PNP or NPN sensor through isolated inputs rated 3.3V to 24V.
Yes, as long as both machines are within cable reach of the counter. Each channel keeps its own count, and Atrium’s Productivity Monitor can report them as two separate assets, so a pair of side-by-side presses or fillers needs only one device to mount, one battery to change, and one mesh connection.
Yes. Both channels arrive together, so you can overlay them on a single graph, build a widget for the ratio between them, and set triggers on that ratio. Alerts can fire when yield falls below target or the reject rate climbs, not only when raw output drops.
Yes. This is a standalone wireless counter that reads directly from your sensors, so you do not need to tap into the PLC or run new cable to a control cabinet. That makes it a practical fit for older machines, leased equipment, or lines where PLC access is restricted.
Yes. The counter uses an open communication protocol, and the Atrium gateway supports MQTT, Modbus TCP, Node-RED, and a REST API. Both channels’ counts and runtime data can flow into any MES, CMMS, or ERP alongside your existing tools.
No. Both channels share one radio and report in the same transmission, and it’s the radio, not the counting, that dominates power draw. The counter runs up to 5 years on a D-cell with Supercap. Note that the D-cell powers the counter itself, not any connected sensors — powered photo eyes and proximity switches run from their own external supply. If you prefer wired power, an external power connector with automatic battery failover is also available.
The counter reaches up to roughly 2 miles line-of-sight on the 868/900MHz models and about 1 mile on 2.4GHz, using long-range wireless mesh networking. In dense indoor environments expect around 1000 ft on 868/900MHz; the self-healing mesh extends coverage by routing through other NCD sensors.
No. The counter sends data to your own Atrium gateway or system with zero monthly software fees. You own your production data outright and can keep it on your network or forward it to any MES, CMMS, or cloud platform, with no recurring costs and no vendor lock-in.
Yes. The counter is housed in an enclosure rated IP65 and NEMA 1,2,4,4X,12,13 with UL-508 listing, and the electronics are rated from -40°C to +85°C. Isolated inputs add protection against the electrical noise common on the plant floor, and the unit mounts to a wall or magnetically.
The IoT Wireless 2 Channel Production Counter is designed and manufactured in-house in the USA by National Control Devices, and it is RoHS compliant. NCD has shipped industrial IoT hardware to more than 7,000 customers, and you own both the hardware and the data it produces.
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 ForumOne purchase. Full ownership. The ratio that actually runs your line.
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