Summary: Use this guide to troubleshoot when production counts are higher than actual output due to double counting, false triggers, or data spikes.
Symptom
You may be experiencing this issue if:
The counter increases by 2–3 when only 1 product passes
Counts are consistently 2x or 3x actual production
Random counts occur when nothing passes
Sudden unrealistic spikes appear in production data
Prerequisites
Before you begin, please confirm:
The DUO is powered on
The sensor is securely mounted and wired correctly
You can observe live counting behavior while products pass
Diagnostic Steps
Follow these steps in order.
Verify debounce value is not too low
What to check: Review the debounce setting in the DUO configuration.
What result indicates success: Debounce is high enough to prevent multiple triggers from one product.
If result is not correct, increase debounce incrementally (start at 5,000 µs and adjust as needed), then test with 10 manual passes.
Observe sensor behavior during one product pass
What to check: Watch the sensor LED and DUO LED during a single product pass.
What result indicates success: Both LEDs activate once per product.
If result is not correct, inspect for mechanical vibration, reflective surfaces, or product features causing multiple triggers.
Review historical data for spikes
What to check: Identify unrealistic spikes in the data.
What result indicates success: Spikes do not reoccur after debounce adjustment.
If result is not correct, inspect for electrical noise or unstable wiring.
Common Root Causes
- Cause 1:
Debounce set too low, allowing multiple triggers per product.
Increase debounce time and validate against live production.
- Cause 2:
Mechanical vibration or electrical noise causing false triggers.
Secure mounting, inspect wiring, and eliminate environmental interference.
Resolution
Once resolved:
Each product results in one count only
No random counts occur when the line is idle
No unrealistic spikes appear in data
If The Issue Persists
Contact Support and include:
DUO serial number
Current debounce value
Screenshot of recent spike timestamps
Video showing sensor behavior during one product pass