PRODUCTION RATE COUNTER When closure is detected on a remote input, the DS017E-

RATE responds according to the operating mode and the

DS017E-RATE setup values you define.

A bright red four-digit display on the face of the DS017E-

RATE shows current values. LEDs to the right of the
numeric display show when the line is at or above goal
(green), idle or reset (yellow), or producing but below
goal (red).

Multiple optional larger external displays may also be

attached to the unit to show what it shows, both numeric
displays and RYG lamps.

With each new signal pulse signifying another event to

count or another item produced, the decimal point for the
least-place character (i.e., at right) will toggle off or on,
reversing with each new signal pulse.
The DS017E-RATE shows a production line’s process
rate, or compares it to a goal you define. Its advantages
are: CONTROLS (from left to right, across the
lower front of the front panel)
1 Automatic Rate Count: Know your production and
Momentary Description
rate of production automatically. Avoid manual rate
Buttons
measurement, hand timing and calculation with the
DS017E-RATE. It gives you more time to focus on your Actual Count Display the actual count or
priorities. difference between the actual count
and the goal count.
2 Show Difference From Goal: The automatic, instant Actual Rate Display the actual rate or difference
calculation of when a lines meets/exceeds goal, falls between the actual rate and the goal
behind or is idle, alerts you and workers with easy-to- rate.
understand color-coded lights, and (if desired) a display
of the difference. Everyone can see at a glance when Goal Display the goal rate in units per
problems occur and when things run properly, so you minute or units per hour or display
accomplish more. You can focus elsewhere when the the running goal count.
green light shows your lines are on target. Select Step to the next function while
changing settings.
3 Higher Production Rates: The pacing feature helps
workers fall into a smooth and steady rhythm. Press and Hold
Production increases when pacing helps workers reach Buttons.
the optimum steady rate of work, so the system pays for Actual Count Clear the actual count to zero.
itself.
Actual Rate Clear the rate counter and rate
4 One Counter, Four Production lines: One single averages.
DS017E-RATE can monitor up to four (4) production Goal Rate Reload power up defaults and clear
lines, and calculate and show the summed rate of all all counters and averages.
those lines.
Select Enter the setup mode.
It requires 9-12VDC or 9-12VAC for operation. AC Knob Change the selected setting.
power provides power-line accuracy to the DS017E-
RATE.

Alzatex, Inc. www.alzatex.com 1 11/08/09

 SETUP

Press the SETUP button to show or change configuration

settings. You enter Setup looking at function one, Mode
Setting. Pressing Select steps to the other settings. Setup
Rate counter inputs and Outputs functions are described below:
Description
1 Mode (see Modes, below)
Input 1 Resets the counters to zero. 2 Pause Clearance Delay (in seconds) *
Input 2 Increment the count by 1. 3 Average Basis (Lower Digits)
4 Average Basis (Upper Digits)
Input 3 Increment the count by 1. 5 Production Goal (Lower Digits)
Input 4 Increment the count by 1. 6 Production Goal (Upper Digits)
Output 1 Pulses at the goal rate. This output
pulses once each time the goal count To make a change, dial in a new value. SELECT steps
increments. from function to function to help you get to the function
you need.

Rate counter serial data Output to Large LED or You can exit from the Setup process by pressing any
video displays. other button.
Format: Description The values for these functions are retained through a
“Laxxxxxx power failure. However, since power spikes and surges
Display 0 Display the local controller can occur when power comes back on, and those spikes
display. and surges can unpredictably alter memory settings and
therefore the values, it’s good to recheck settings when
Display A Display the actual count. (range power comes back on after an outage.
0 to 999999)
Display B Display the goal count. (range 0
to 999999) RESET
Display C Display the difference between
the goal count and the actual Clear the actual count and the goal count. Press and hold
count. the Actual Count button button for 2 seconds.
(range -99999 to 999999)
Clear the actual rate and the goal rate. Press and hold the
Display D Display the actual rate. (range 0
Actual rate button button for 2 seconds.
to 9999)
Display E Display the goal rate. (range 0 to Reset all parameters to the power up values and clear all
9999) counters. Press and hold the Goal Rate button button for
2 seconds.
Display F Display the difference between
the goal rate and the actual rate.
(range -999 to 9999)
DISPLAY
Indicators Display the RYG status.
Green=Goal> actual;
The Goal Count button changes the display between
Red=Goal<actual;
Actual Count and the Difference between Actual and
Yellow=Paused
Goal Count.

Actual Count shows the actual count

Difference shows the difference between the actual rate,

and the goal rate, as defined in Setup Goal Count.

Alzatex, Inc. www.alzatex.com 2 11/08/09

EXAMPLES:

If the Actual count is 233, and 200 items were 0.0.3.0.

produced, the Difference shows as:
33
If the Actual count was 195, and 200 items
were produced, the Difference would be :
- 5
The Actual Rate button changes the display between
Actual Rate and the Difference between Actual and
Goal Rate.
Actual Rate shows the actual rate.
If the Goal rate is 30 units per hour, two hours
has passed, the running goal count will be:
60
SELECT
The SELECT button steps to the next choice once you’ve
started with SETUP. Press SELECT to step to each
function in turn, cycling through the values of the six
different functions. You start in 1 Mode, and pressing
SELECT six times returns you to function 1 Mode. You
may avoid changing values in functions you don’t want
to change, by pressing SELECT without moving the dial.

Difference shows the difference between the actual

rate, and the goal rate, as defined in Setup Goal Rate. Knob
EXAMPLES: You can dial in changes to setup and mode values using
the dial on the front panel. As soon as you make a
If the Actual rate was 195/hour, and 200 items change, the new value is stored. If you don’t alter a
were produced in an hour, the Difference setting before the counter either receives another signal
would be : pulse (indicating another item counted), or press the
DISPLAY or RESET buttons, the value originally shown
- 5 when you entered Setup will not change.

If the Actual rate is 146/hour, and the goal is

150/hour, the Difference would show as - 4
If the Actual rate is 175/hour, and the goal is
150/hour, the Difference would be:

25
The Goal Rate button changes the display between
Goal Rate and the Running Goal Count.

Goal Rate shows the goal rate in units per minute or

units per hour.

The Running Goal Count increments at the goal rate,

as defined in Setup Goal Rate.

EXAMPLES:

If the Goal rate is 30 units per minute, the goal

rate is displayed as:

Alzatex, Inc. www.alzatex.com 3 11/08/09

 2 Pause Clearance Delay in seconds
CHOICES CONTROLLED BY
SETUP (1-6) Auto-Clear must be enabled to use this feature (requires
Mode 2, 3, 5 or 7). When setting the Pause Clearance
Delay, the decimal points after each digit on the display
are all dark. This should be set to from one (1) to 99
1 Modes (ninety-nine) seconds.

When entering into Modes from Setup, the decimal 3 Average Basis (Lower Digits)
point after the least-significant digit (i.e., rightmost) is
lit. When setting the Average Basis (Lower Digits), the
decimal points after each digit are all dark. Both upper
Eight modes, numbered from 0 to 7, represent a matrix and lower digits will display, but you can only alter the
of three different conditions. Here’s a table, showing lower digits in this step.
the three conditions, and the modes for each condition
when its value is set to 0 or off. This value is the lower two digits for the raw number of
events (items produced, or signal pulses received by the
DS017E-RATE) to use as the basis for averaging. Examples:
MODES Bit 2 Bit 1 Bit 0
0 0 0 0 If you want to know the average rate for the past
1 0 0 1 two minutes (2) and the typical rate is 20
2 0 1 0 (twenty) units per minute, set the Rate Average
3 0 1 1 (Lower Digits) to 2 times 20 or 40 (fourty) and
4 1 0 0 00 as the Rate Average (Upper Digits). The rate
5 1 0 1 counter will display the average production rate
6 1 1 0 for the most recent 40 events.
7 1 1 1
For a rate average of 25 per minute over 10
Bit 0: Goal count time basis: Calculate the goal minutes, or a count of 250 as the basis for
and averaging, per: 1 = Hour, 0 = Minute. averaging, enter the last two digits, 50, as the
Rate Average (Lower Digits), and 02 as the Rate
Bit 1: Auto-clear: When a pause over nn seconds* Average (Upper Digits). The rate counter will
occurs: 1 = Clear the counter, 0 = Pause counting. calculate and show the average production rate
for the most recent 250 units produced.
Bit 2: Sequencer Lights: 1 = Enable, 0 = Disable.
4 Average Basis (Upper Digits)
Example: If you want to use the sequencer lights, your
choices are modes 4 5 6 7. When setting the Average Basis (Upper Digits), the
If you want also to pause counting when a pause of decimal points after each digit are all lit. All digits will
greater than nn seconds* happens, select from modes 0 display, but you can only alter the upper digits in this
1 4 5. step. This value should be the upper two places of the raw
If a count by minutes is desired for goals and averages, number of events (items produced, or signal pulses
modes 0 2 4 6 would work. received by the DS017E-RATE ) to use as the basis for
averaging, as explained in 3 Average Basis (Lower
The mode providing all three conditions is mode 0. Digits) above.

* Make sure not to leave the Pause Clearance Delay set
to 0, else spontaneous clearances of counter and rates
may occur.
5 Production Goal (Lower Digits)
The Production Goal serves two functions. If a beeper or
other feedback device, audio or visual, is connected, the
output sent to it pulses at the production goal rate. Also,
if the display is set to Difference, the difference between
goal and actual rate is shown.

Alzatex, Inc. www.alzatex.com 4 11/08/09

When setting the Production Goal (Lower Digits), the
decimal points after each digit are all lit. Both upper
and lower digits will display, only the the lower digits
can be altered in this step. Enter the lower two digits of
your production goal, in events per minute or events per
hour. Exampes:
If the typical rate is 20 (twenty) units per
minute, and the Goal count time basis is set to
minutes, set the Production Goal (Lower
Digits) to 20 (twenty) and the Production Goal
(Upper Digits) to 00.
If the typical rate is 250 (two hundred and
fifty) units per hour, and the Goal count time
basis is set to hours, set the Production Goal
(Lower Digits) to 50 (fifty) and the Production
Goal (Upper Digits) to 02.
6 Production Goal (Upper Digits)
When setting the Production Goal (Upper Digits),
decimal points after each digit are all lit. All digits will
display, but only the upper digits can be changed in this
step. See 5 Production Goal (Lower Digits) for
details.
SETUP WORKSHEET
Before showing some Setup examples, let’s determine
a few things. Here’s a checklist which will help,
covering the six Setup functions.
1. First, let’s review your choices of Modes.
1. Hour (choose one of the Modes 1, 3, 5, or 7)
or
2. Minute (choose one of the Modes 0, 2, 4, or
6)
The mode in common to your answers for the three
questions above tell you which mode to choose in the
first function of Setup. The chart on page 3 can be
helpful here.
Now, move on to the other items to determine. (Different
fields in examples below have different kinds of
underlining).
2. Pause Clearance Delay: How long should the above
pause be, in seconds, from 1 to 99?
We’ll skip over items 3 & 4 for a moment, and move on
to items 5 & 6. What’s your production goal, the raw
number, per hour or per minute? How many items do
you want the line to be paced against?
5. Production Goal (Lower Digits): The least
significant two digits, the two on the right, go here
6. Production Goal (Upper Digits): The most
significant two digits, the two on the left, go here
Now, let’s go back to items 3 & 4. You chose above, in
1B, whether you measured in items/hour or items/minute.
You also chose above, in items 5 & 6, your numeric goal.
Multiply the raw number of items times the number of
minutes or hours you want to count the average in.

A. Do you have reliable 60Hz (“60 cycle”) AC

power? (Choose one of the Modes 0, 1, 2, or 3. Average Basis (Lower Digits): The least significant
3). Alternatively, you can use the internal two digits, the two on the right, go here
100Hz timer (choose one of the Modes 4, 5, 6,
or 7) which has 50 ppm accuracy. 4. Average Basis (Upper Digits): The most significant
two digits, the two on the left, go here
B. When there’s a pause of (99 seconds or less) in
the signals from your system which signify
another item’s produced, do you want to

1. Clear the counter timer (choose one of the

Modes 2, 3, 6, or 7)
or
2. Pause Counting? (choose one of the
Modes 0, 1, 4, or 5)

C. Do you want to set your goal in items per

Alzatex, Inc. www.alzatex.com 5 11/08/09

OPTIONS
OPTICALLY-COUPLED INTERFACE PERMITS
SAFE AND RELIABLE CONNECTION TO
MACHINERY
An optional optically-coupled, electrically-isolated
interface is available. Removing a direct electrical
connection to other equipment eliminates the possibility
of ground loops, diminishes chances of interference and
increases safety.
SEVEN SEGMENT DISPLAY WITH LARGE
DIGITS FROM 2.33” (5.9cm) TO 36" (91.4cm)
TALL
ACCURACY
If DC power is used to control the DS017E-RATE, the
internal time reference must be selected by choosing one
of the modes numbered four (4) through seven (7).
Using the internal time reference provides 50ppm
accuracy. The AC power line frequency in most areas of
the United States and Canada has a long-term accuracy of
three to five seconds per year, but short term inaccuracies
may occur.
At production rates of more than ten times the time
reference frequency, whether derived from the 60Hz
power line or the 100Hz internal oscillator, the DS017E-
RATE may be inaccurate.

Small, large and very large external displays may be
added to repeat what the internal display shows.
Displays can be directly wired, connected through a
network, or radio can be used for wireless control.
ANDON RED / YELLOW / GREEN INDICATOR
LIGHTS SHOW ABOVE OR AT GOAL / BELOW
GOAL
Small, large and very large external lights may be added
to show when a production line is below (red), idle
(yellow) or at or above the current goal (green).
Displays can be directly wired, connected through a
network, or radio can be used for wireless control.
ANDON FLASHING AT GOAL RATE TO PACE
WORKERS
Electrical power, whether AC or DC, should be
connected to the DS017E-RATE, not connected only to an
external display. Some external displays do not have
internal time references. The 100Hz internal time
reference must be used in these applications.
USE OUTSIDE OF NORTH
AMERICA
The standard DS017E-RATE is not designed for 50Hz
power line frequencies found in many places outside of
North America. Use the 100Hz internal reference when
only 50Hz power is available.

An optional output from the DS017E-RATE sends a signal

pulse when an event should occur, based on the goal set
and elapsed time. That signal could control a flashing
light or other feedback device to encourage an efficient
rhythm of production, to set a pace for work. An LED
on the circuit board blinks when that pulse would be
sent.

BEEPER OR HORN SOUND AT GOAL RATE TO

INDICATE WHEN AN ITEM SHOULD BE
COMPLETED

An optional output from the DS017E-RATE signals every

time an event should occur, based on the programmed
goal and elapsed time. That signal could drive a chime,
horn, buzzer, beeper, or other feedback device to
encourage an efficient rhythm of production. An LED
on the circuit board blinks to show when that pulse
would be sent.

Alzatex, Inc. www.alzatex.com 6 11/08/09

 C. Two displays may be connected using an RJ-45
INSTALLATION CONNECTIONS splitter, but a large display may require its own
power supply. If so, make sure the DS017E-RATE
has a reliable power supply of its own.
Sensors:
D. If the distance between the DS017E-RATE and an
A. Direct Connection: Connect pins 6 and 8 on
external display will be long, use a ‘crossover’
the eight-pin polarized connector to a sensor
six-wire cable with an RJ25 modular phone type
on customer’s equipment. When closure of the
connector to a KT422 type interface between the
circuit is sensed, the counter will recognize it
DS017E-RATE and the display, with a
as another count.
prefabricated 4 wire cable of 100’ or less
between the KT422 and the display. The display
B. Isolated Connection (Optional): Use an opto-
side uses a 4-pin round connector plug. Color
isolator, with the output from the isolator
codes for wiring small displays are: V=Red,
connected to pins 6 and 8 on the eight-pin
G=Black, A=Green and B=White (if problems
polarized connector.
occur, try switching A and B); larg displays use
+V=Red, GND=Black, RX+=Green and RX-
=White.
Power Supplies (Three options):

A. Plug a 9-12V AC transformer into a 60Hz

standard wall outlet. The supply’s coaxial
connector plug is inserted into the matching IN
connector on the Main Interface board INSTALLATION PIN ASSIGNMENTS
(KT10260A0).
The DS017E-RATE relies on a sensor connection, direct or
B. Plug a 9-12V DC power supply into a 60Hz isolated, on pins 6 and 8 of the eight-pin polarized
standard wall outlet. The supply’s coaxial connector.
connector plug is inserted into the matching IN
connector on the Main Interface board
(KT10260A0). Make sure to select modes 4, 5, 6
or 7 in the Setup process.

C. Attach a supply’s coaxial connector plug to a

cable from a 12V DC battery into a 60Hz standard
wall outlet. The supply’s coaxial connector plug is
inserted into the matching IN connector on the
Main Interface board (KT10260A0). Make sure to
select modes 4, 5, 6 or 7 in the Setup process.

External Displays: All attach to the TX (out) port on

the DS017E-RATE

A. Alzatex external digital displays run by a

KT10260 type controller attach using a
standard CAT-3 or better network cable, with
RJ-45 eight-pin connectors on each end, with a
run of 100’ or less.

B. Alzatex external RYG displays attach using a

standard CAT-3 or better network cable, with
RJ-45 eight-pin connectors on each end, with a
run of 100’ or less.

Alzatex, Inc. www.alzatex.com 7 11/08/09