When the count of produced results in a process does not match the total of results in edinn, these are the verifications to be performed based on the most common reasons:

  1. Check if the pulse is really arriving to the eBOX: for example, if the sensor is photoelectric, some results could have a label which reflects the beam of the sensor and that prevents the sensor from counting. You can check if the PLC is really receiving the pulse by checking the LED on the input of the PLC (inside the eBOX) every time a result passes by the sensor. The typical fix to this problem is adjusting or changing the sensor to a most suitable one.
  2. Check if the frequency of pulses is higher than the one accepted by the eBOX or its program: in some cases, when results’ pulses are generated fast (typically faster than 20 /second), although you can see the LED blinking, some pulses are being lost. If frequency of production is higher or similar to 20/sec., the typical fix to this is to change the program of the eBOX and reduce the time filters, or to change the eBOX to a faster one.

NOTE: If you choose full service with an eHUB, you do not have to perform the following steps.

  1. Check if the counter or counters meet with the minimum requirements of how a counter must be and if its reset value is correctly configured in the monitor.
  2. Check if the OPC Server is counting as many as you are producing: once confirmed the previous steps, open the OPC Server and check, during a long enough period, that the results produced are all counted by the OPC Server. If the previous steps were not cause of problems and if the OPC Server is working correctly, there should not be any difference to the real production.
  3. Check that the same count of the OPC Server has arrived to edinn in results: this step should only be performed after the previous steps have been performed. Reasons to possible differences could be:
    • The process was in a status which was blocking results. Please see status configuration.
    • The process was producing faster than the rate accepted by the % of minimum cycle time configured in the monitor. Please see “minimum percentage of the cycle time”.
    • A user has deleted results: this can be checked by searching for the word “deleted” in the logs of the server in the Console (please see how to view the server logs). All user manual deletions of records are shown that way in the server Logs independently of the log detail, user roles, etc.

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