MTConnect Connectivity Guide

• Overview
  • What is MTConnect?
  • Why MTConnect is Preferred
  • Who This Guide is For
• Compatible Machines
  • Machine Tool Brands
  • Control Systems
  • CMM Equipment
• Prerequisites
• How MTConnect Works
  • Architecture
  • Data Flow
  • Ports and Endpoints
• Verifying MTConnect Support
  • Quick Test Method
  • Control-Specific Checks
• Physical Connection
  • Network Setup
  • Wired vs Wireless
• Enabling MTConnect
  • Generic MTConnect Setup
  • Mazak-Specific Setup
  • Okuma-Specific Setup
  • Hexagon CMM Setup
  • Zeiss CMM Setup
• Adding the Machine in MachineMetrics

• Configuring Data Collection
  • Available Data Items
  • Part Counting
  • Multi-Machine Agents
• OEM-Specific Configurations
  • Mazak
  • Okuma
  • Hexagon CMMs
  • Zeiss CMMs
  • Other MTConnect Machines
• Troubleshooting
  • Connection Issues
  • No Data Appearing
  • Mazak MTConnect Service Issues
  • Okuma Issues
  • Network Problems
• Best Practices
• Additional Resources
• Getting Help

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Overview

What is MTConnect?

MTConnect is an open-source, royalty-free standard for collecting data from manufacturing equipment. Developed and maintained by the MTConnect Institute, this standard enables manufacturing equipment to provide data in structured XML format rather than proprietary formats.

MTConnect is one of the most commonly encountered standards that MachineMetrics uses to connect to machines worldwide.

Key Characteristics:

• Open and standardized protocol
• XML-based data format
• Industry-wide adoption
• No licensing fees
• Supported by major machine tool builders

Why MTConnect is Preferred

When a machine supports MTConnect, it's typically the preferred connectivity method because:

1. Standardized: Consistent data format across different manufacturers
2. Rich Data Set: Comprehensive machine status, alarms, programs, and production metrics
3. Simple Setup: Often requires only network configuration
4. No Additional Hardware: No serial converters or I/O modules typically needed
5. Fast Deployment: Can usually connect in 20-45 minutes
6. Industry Support: Continuously evolving with industry needs

Who This Guide is For

This guide is for:

• Manufacturing engineers connecting MTConnect-capable equipment
• IT personnel configuring network access for machines
• Maintenance staff enabling MTConnect on controls
• Quality engineers connecting CMM equipment
• Anyone responsible for machines with MTConnect capability

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Compatible Machines

Machine Tool Brands

Many well-known machine tool brands now include MTConnect as a standard or optional feature:

Common MTConnect-Enabled Brands:

• Mazak - Smooth and Matrix controls (2010+)
• Okuma - OSP 300, OSP 200, OSP 100-II
• Hurco - WinMax 10.4.0+ (mill) or 11.3.4+ (lathe)
• DMG MORI - Various controls
• Haas - Next Gen controls (port 8082)
• Doosan - Recent models
• Many others - Check with your machine manufacturer

Control Systems

Mazak Controls:

• Mazak Smooth (SmoothX, SmoothG, SmoothAi)
• Mazak Matrix controls
• Generally 2010 or newer models
• See Supported Mazak Control Models section

Okuma Controls:

• OSP 300 (best support)
• OSP 200 (requires THINC API update)
• OSP 100-II (requires THINC API update)
• Other OSP 100 controls: NOT supported

Hurco Controls:

• WinMax 10.4.0 or later (mills) - MTConnect included
• WinMax 11.3.4 or later (lathes) - MTConnect included
• Older WinMax versions - Requires Ultimonitor option
• Uses MTConnect version 1.3 schema
• Port 5000 (default)

Others:

• Varies by manufacturer
• Check machine documentation
• Contact MachineMetrics for verification

CMM Equipment

Hexagon CMMs:

• PC-DMIS 2019 R1 or later
• QUINDOS Version 8.1 or later
• Requires MTConnect Exporter license

Zeiss CMMs:

• CALYPSO 7.2 or newer
• PiWeb 8.x or newer
• Requires MTConnect Data Interface license

Other CMMs:

• Contact CMM manufacturer for MTConnect support
• May require software updates or licenses

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Prerequisites

Before connecting your MTConnect machine, ensure you have:

Hardware:

• Machine with MTConnect capability (verified)
• MachineMetrics Edge device (deployed and activated)
• Ethernet cable (CAT5/CAT6)
• Network access between machine and Edge device

Network:

• IP address for the machine
• Knowledge of MTConnect agent port (typically 5000, or 8082 for Haas)
• Firewall access for MTConnect agent port
• Ability to test connectivity (ping, browser)

Access:

• Physical access to machine control
• Permission to enable MTConnect (if not already enabled)
• Administrative access to Windows backend (for Mazak, Okuma)

Information:

• Machine make, model, and control type
• Control software version
• Current network configuration

For CMMs:

• MTConnect license (Hexagon or Zeiss)
• CMM software version
• Administrator permissions on CMM PC

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How MTConnect Works

Architecture

MTConnect uses a client-server architecture:

Machine Control
     ↓
MTConnect Adapter (converts machine data to SHDR format)
     ↓
MTConnect Agent (serves XML data via HTTP)
     ↓
MachineMetrics Edge Device (ingests and processes data)
     ↓
MachineMetrics Cloud

Components:

• Adapter: Translates machine-specific data to SHDR (Simple Hierarchical Data Representation)
• Agent: HTTP server that provides XML data streams
• Client: MachineMetrics Edge device that consumes the data

Data Flow

1. Machine control generates operational data
2. MTConnect Adapter reads this data
3. Adapter converts data to SHDR format
4. Agent receives SHDR and converts to XML
5. Edge device polls the Agent's HTTP endpoint
6. Edge processes and sends data to MachineMetrics Cloud

Ports and Endpoints

Common MTConnect Ports:

• 5000: Agent port (most common default)
• 7878: Adapter port (Mazak and some others)
• 8082: Agent port (Haas Next Gen)
• Custom: Some implementations use different ports

Note: MTConnect uses two types of ports:

• Agent ports (e.g., 5000, 8082) - External HTTP endpoint for data collection - Test with web browser
• Adapter ports (e.g., 7878) - Internal connection between adapter and agent - Test with telnet

Testing Adapter Ports:

To test if an adapter is running on port 7878, use telnet (not a web browser):

telnet <machine-ip> 7878

Example:

telnet 192.168.1.100 7878

If the adapter is running, you should see streaming data. If it doesn't connect, the adapter service is not running.

Common Endpoints:

• /probe - Returns agent configuration and available data items
• /current - Returns current values for all data items
• /sample - Returns historical time-series data
• /assets - Returns asset information (tools, fixtures, etc.)

Example URLs:

• http://192.168.1.100:5000/probe
• http://192.168.1.100:5000/current
• http://192.168.1.100:8082/sample (Haas)

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Verifying MTConnect Support

Quick Test Method

Follow these steps to check if your machine produces MTConnect data:

Step 1: Ensure Network Connection

1. Connect machine to network via Ethernet
2. Configure static IP address on machine
3. Note the IP address (e.g., 192.168.1.100)

Step 2: Test Connectivity

1. From a computer on the same network
2. Open Command Prompt or Terminal
3. Ping the machine: ping 192.168.1.100
4. Verify you receive replies

Step 3: Test MTConnect Endpoint

1. Open a web browser
2. Try these URLs (replace IP with your machine's IP):
   • http://192.168.1.100:5000
   • http://192.168.1.100:8082 (Haas only)
3. Add /current to the URL for current data
4. If you see XML data, MTConnect is working!

Step 4: Verify on Control (Windows-Based)

For machines with Windows backend (Mazak, Okuma):

1. Access Windows backend on the machine control
2. Open browser on the control
3. Navigate to http://127.0.0.1:5000 or http://127.0.0.1:7878
4. Or try http://localhost:5000/current
5. If data appears here but not from external PC: firewall issue

What Success Looks Like:

You should see XML output similar to:

<?xml version="1.0" encoding="UTF-8"?>
<MTConnectStreams ...>
  <DeviceStream name="Machine1">
    <ComponentStream component="Controller">
      <Samples>
        <Execution>READY</Execution>
        ...

If No Data Appears:

• MTConnect may not be enabled
• Port may be different
• Firewall may be blocking access
• Software upgrade may be needed

Control-Specific Checks

For Mazak:

1. Access Windows backend (click Start button)
2. Search for "MTConnect"
3. Look for MTConnect folder with associated files
4. If found: MTConnect is installed
5. If not found: Contact Mazak for installation files

For Okuma:

1. Access Windows backend (press CTRL + ///)
2. Use Scout tool at MyOkuma.com to check compatibility
3. Navigate to Programs → Okuma → MTConnect
4. If present: MTConnect is installed
5. Check THINC API version (may need update)

For CMMs:

• Check installed software for MTConnect Exporter or Interface
• Verify license is active
• Check Services for MTConnect adapter service

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Physical Connection

Network Setup

Step 1: Connect Ethernet Cable

• Plug cable into machine's Ethernet port
• For Mazak: Port typically patched from HMI to electrical cabinet
• For Okuma: Port on control panel or in cabinet
• For CMMs: Network port on CMM PC

Step 2: Configure IP Address

Static IP (Recommended):

• Access network settings on machine or control PC
• Set static IP address
• Example: 192.168.1.100
• Subnet: 255.255.255.0
• Gateway: 192.168.1.1 (if needed)

⚠️ For Mazak:

• Configure "PC IP Address" (Windows Ethernet settings)
• DO NOT change the "NC IP Address" - this is for internal machine control communication

For Okuma:

• Press CTRL + /// to access Windows
• Configure Ethernet adapter settings
• Set static IP

For CMMs:

• Standard Windows network configuration
• Use static IP for reliability

Step 3: Verify Network Access

• Ensure machine IP and Edge device are on same subnet
• Test with ping from Edge device or computer
• Verify firewall allows MTConnect port

Wired vs Wireless

Wired Connection (Typical):

• Direct Ethernet cable from network to machine
• Most reliable for MTConnect
• Lower latency
• Preferred for production environments

Wireless Connection:

• Edge device with WiFi in machine cabinet
• Edge connects via Ethernet to machine
• Edge communicates to cloud via WiFi
• Useful when cabling is impractical

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Enabling MTConnect

Generic MTConnect Setup

For machines that already have MTConnect installed:

Step 1: Locate MTConnect Service

• Access Windows backend on control
• Search for MTConnect application or service
• Common locations:
  • Start Menu → Programs → MTConnect
  • Windows Services → "MTConnect Agent" or similar

Step 2: Verify Service is Running

• Open Services (services.msc)
• Find MTConnect service
• Status should be "Running"
• If not running: Right-click → Start

Step 3: Configure Network Port

• Open MTConnect configuration utility
• Verify HTTP port (typically 5000 or 7878)
• Ensure port is not blocked by firewall

Step 4: Test Locally

• On the machine control, open browser
• Navigate to http://localhost:5000/current (or your port)
• Verify XML data appears

Step 5: Test Externally

• From another computer on network
• Navigate to http://[machine-ip]:5000/current
• If this fails but local test works: firewall issue

Mazak-Specific Setup

Important: Not all Mazak machines require MTConnect. See the Mazak Connectivity Guide to determine which connection method is appropriate for your machine.

Recommendation:

• If MTConnect is NOT already installed: Use Mazak Fusion Client instead (recommended)
• If MTConnect is already installed: You may continue to use MTConnect

Checking for MTConnect:

1. Access Windows Backend

   • Click Windows Start button on Mazak control
   • The control uses Windows as the OS

2. Search for MTConnect

   • Click Start → Search
   • Type "MTConnect"
   • Look for MTConnect folder

3. Verify Installation

   • MTConnect folder should contain:
     • Adapter executable
     • Agent executable
     • Configuration files
   • If not found: MTConnect needs to be installed

Installing MTConnect (if needed):

1. Contact Mazak

   • Mazak provides MTConnect on a thumb drive
   • Each machine requires individual license file
   • Request one thumb drive per machine
   • Mazak provides installation instructions

2. Supported Control Models

   • See Mazak-Specific Section for detailed compatibility chart
   • Generally 2010 or newer controls support MTConnect
   • Smooth and Matrix control families

Network Configuration:

1. Locate Ethernet Port

   • Port usually patched from HMI
   • Cable runs to keystone in main electrical cabinet
   • Connected to shop network

2. Configure PC IP Address

   • Access Windows network settings
   • Configure Ethernet adapter
   • Set static IP address
   • WARNING: Do NOT change NC IP Address!

3. Default MTConnect Port

   • Mazak agent typically uses port 5000
   • Mazak adapter typically uses port 7878 (internal)
   • Verify in MTConnect configuration

Starting MTConnect Service:

1. Access Control Panel → Administrative Tools → Services
2. Find "Mazak MTConnect" or similar service
3. Ensure Status = "Running"
4. If not: Right-click → Start

Okuma-Specific Setup

Compatibility Check:

1. Determine Control Type

   • OSP 300: Best MTConnect support
   • OSP 200: Requires THINC API update + MTConnect
   • OSP 100-II: Requires THINC API update + MTConnect
   • Other OSP 100: NOT supported

2. Use Scout Tool

   • Visit MyOkuma.com
   • Use Scout tool to verify compatibility
   • Tool will indicate if updates are needed

3. Check Compatibility Chart

   • See full chart at MyOkuma

Accessing Windows:

• Press CTRL + /// to access Windows Start button
• From here you can access File Explorer, applications, etc.

Installing/Updating MTConnect:

1. Check Current Installation

   • Press CTRL + ///
   • Navigate to Programs → Okuma → MTConnect
   • If not present: needs installation

2. Install from THINC App Store

   • OSP 300: Install directly from THINC App Store
   • Download MTConnect Agent/Adapter
   • Follow on-screen installation prompts

3. Update THINC API (if needed)

   • OSP 200 and OSP 100-II require THINC API update first
   • Must be done by Okuma dealer
   • Contact your dealer for this service

Enable Monitoring Tags:

⚠️ Critical Step: Even with MTConnect installed, monitoring must be enabled.

1. Press CTRL + /// (access Windows)
2. Select Programs → Okuma → Okuma MTConnect Adapter Application
3. Enter credentials:
   • Username: Administrator
   • Password: okuma+osp
4. Select Configuration tab
5. Click Tags Configuration button
6. Check "Enable Monitoring Tags"
7. Verify data items you want to monitor are also checked
8. Click Save & Close
9. Restart machine for changes to take effect

Port Configuration:

• Okuma typically uses port 5000
• Verify in MTConnect configuration utility

Part Counting:

See Okuma Part Counting section for configuring common variables if automatic counting doesn't work.

Hexagon CMM Setup

Prerequisites:

• PC-DMIS 2019 R1+ or QUINDOS 8.1+
• MTConnect Exporter License (purchase from Hexagon)
• Windows-based CMM controller
• Network access to MachineMetrics Edge
• Administrator permissions

Installation Steps:

1. Obtain MTConnect License

   • Contact Hexagon support or reseller
   • Purchase MTConnect Exporter license
   • Receive license key or entitlement file

2. Download Installer

   • Download from Hexagon Nexus
   • Or use installation media from Hexagon

3. Install MTConnect Exporter

   • Run installer as Administrator
   • Follow prompts
   • Specify network configuration during install

4. Activate License

   • Launch "MTConnect Exporter Configuration Utility"
   • Enter license credentials
   • Verify service appears as "Licensed"

5. Configure Endpoint

   • Set machine name
   • Set HTTP port (default 5000)
   • Configure PC-DMIS/QUINDOS data path
   • Click "Apply and Start Service"

6. Test Locally

   • Open browser on CMM PC
   • Navigate to http://localhost:5000/current
   • Should see XML with <MTConnectDevices> or <MTConnectStreams>

Data Flow:

1. CMM's control PC runs PC-DMIS or QUINDOS
2. MTConnect Exporter service translates machine state and measurement data
3. Data served at HTTP endpoint (e.g., http://[CMM-IP]:5000/current)
4. MachineMetrics Edge polls endpoint and ingests data

Zeiss CMM Setup

Prerequisites:

• CALYPSO 7.2+ installed and licensed
• Zeiss MTConnect Data Interface license
• Windows 10/11 64-bit PC
• Network access to MachineMetrics Edge
• Administrator permissions on controller PC

Installation Steps:

1. Obtain Installer

   • Request from Zeiss support representative
   • Or download from Zeiss Portal account
   • Free 60-day trial available

2. Run Installer

   • Execute as Administrator on CMM PC
   • Accept default path: C:\Program Files\Zeiss\MTConnectAdapter

3. Activate License

   • Open Zeiss License Manager
   • Import MTConnect entitlement file
   • Verify "MTConnect Interface" shows as "Licensed"

4. Configure Adapter

   • Launch "MTConnect Configuration Utility"
   • Set machine name
   • Set HTTP port (default 5000 or 5001)
   • Configure CALYPSO data path
   • Click "Apply and Start Service"

5. Test Locally

   • On CMM PC, open browser
   • Navigate to http://localhost:5000/current
   • Should see XML output with MTConnect data

Data Items Available:

• Machine status (Idle / Measuring / Alarm)
• Current part program name
• Measurement count and cycle time
• Operator ID (if configured)

Hurco-Specific Setup

Overview:

Hurco machines use the MTConnect protocol to retrieve manufacturing data directly from WinMax on the control. The MTConnect adapter is available for download and installation.

Important: Hurco provides data through the MTConnect protocol but does not provide a GUI interface to display the data. Ensure any third-party applications (including MachineMetrics) check against MTConnect version 1.3 scheme.

Prerequisites:

• WinMax Version Requirements:
  • Mill: WinMax 10.4.0 or later (MTConnect available without Ultimonitor)
  • Lathe: WinMax 11.3.4 or later (MTConnect available without Ultimonitor)
  • Older versions: Require Ultimonitor option to use MTConnect
• Administrator access to Hurco control
• Network connectivity between machine and Edge device

Installing the MTConnect Adapter:

1. Download MTConnect Adapter

   • Download from Hurco MTConnect download page
   • Password: mtconnect

2. Access Service Menu

   • Select Windows key or Hurco icon button on control
   • Select the Service softkey
   • Enter password: 46268
   • Click OK

3. Enable Drive Access

   • In Hurco Service Window, select Toggle Drive Access On
   • Button will change to read "Toggle Drive Access Off"

4. Open File Explorer

   • In Hurco Service Window, select Open Explorer
   • Close the Hurco Service Window (click X in upper right)

5. Run Installer

   • Search for MTConnect install package in File Explorer
   • Select Run to launch installer
   • Check box to accept License Agreement terms
   • Click Install button
   • Click Finish after successful installation

Verifying Installation:

Method 1: Using Internet Explorer

1. Access Shell menu (Windows key or Hurco icon)
2. Select Run softkey
3. Enter password: 46268
4. Enter iexplore in Run window and click OK
5. Enter http://127.0.0.1:5000/current in address bar
6. Press Enter
7. Verify: Machine data should display in XML format
   • If data appears, MTConnect adapter is running correctly

Method 2: Using Task Manager

1. Access Service menu (password: 46268)
2. Enable Drive Access
3. Select Task Manager
4. Close Hurco Service Window
5. Select Processes tab
6. Verify: Look for these processes:
   • agent.exe
   • MTConnectAdapter.exe
   • If both are running, adapter is working

Port Configuration:

• Default Port: 5000
• Test URL: http://127.0.0.1:5000/current (local)
• External URL: http://[MACHINE-IP]:5000/current (from network)

Data Items Available from Hurco:

Hurco MTConnect provides the following data:

Data Item	Description
Status & Control
EStop_State	Emergency stop status
Feed_Hold	Feed hold status
Controller_Mode	Current controller mode
Machine_Mode	0=Diagnostic, 1=Idle, 2=Manual, 3=Manual Setup, 4=Auto Prep, 5=Auto Run, 6=Interrupt Cycle
COR_Status	Corner rounding status
Program Info
Program_Name_Running	Active program name
Program_Name_Editing	Program being edited
Program_Status	Current program status
Block_Number	Current block number
Program_Runtime_Seconds	Program runtime
Part_Count	Part counter
Spindle & Feed
Spindle_Speed	Current spindle speed
Spindle_Override	Spindle override percentage
Spindle_Time	Total spindle run time
S_Axis_Load	Spindle load
Feed_Rate	Current feed rate
Feed_Override	Feed override percentage
Rapid_Override	Rapid override percentage
Rapid_Speed	Rapid traverse speed
Tooling
Current_Tool	Active tool number
Positioning
X_Position, Y_Position, Z_Position	Axis positions
A_Position, B_Position, C_Position	Rotary axis positions
W_Position	W axis position
Axis Loads
X_Axis_Load, Y_Axis_Load, Z_Axis_Load	Linear axis loads
A_Axis_Load, B_Axis_Load, C_Axis_Load	Rotary axis loads
W_Axis_Load	W axis load
Other
Machine_Time	Total machine time

Troubleshooting Hurco MTConnect:

Problem: Cannot access http://127.0.0.1:5000/current

Solutions:

1. Verify MTConnect adapter is installed
2. Check Task Manager for agent.exe and MTConnectAdapter.exe processes
3. If processes not running:
   • Restart machine
   • Reinstall MTConnect adapter
4. Check Windows Firewall settings (port 5000 must be allowed)

Problem: Local test works but external access fails

Solutions:

1. Verify machine IP address
2. Ping machine from Edge device or computer
3. Check network connectivity
4. Verify Windows Firewall allows external connections on port 5000
5. Check if machine is on same network/VLAN as Edge device

Problem: Wrong WinMax version

Solution:

• If WinMax is older than 10.4.0 (mill) or 11.3.4 (lathe):
  • Option 1: Upgrade WinMax to supported version
  • Option 2: Purchase and install Ultimonitor option
  • Contact Hurco support for upgrade options

Adding Hurco to MachineMetrics:

After verifying MTConnect is running:

1. In MachineMetrics, go to Assets → Machines
2. Click Add Machine
3. Enter machine details:
   • Machine Name: (e.g., "Hurco VM10i")
   • Make: Hurco
   • Model: (e.g., "VM10i")
   • Edge Device: Select your Edge
4. Select adapter type: MTConnect Agent
5. Enter connection details:
   • Connection address: [MACHINE-IP]:5000
   • Example: 192.168.1.100:5000
6. Click Test Connection
7. If successful, click Save

Additional Resources:

• Hurco MTConnect Installation Guide
• Hurco Support: Contact your Hurco dealer
• MTConnect Version 1.3 Schema: mtconnect.org

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Adding the Machine in MachineMetrics

Once MTConnect is enabled and verified:

Step 1: Log into MachineMetrics

• Navigate to Assets → Machines
• Click Add Machine

Step 2: Enter Machine Details

• Machine Name: Descriptive name (e.g., "Mazak-Mill-1")
• Make: Manufacturer (e.g., "Mazak", "Okuma")
• Model: Machine model
• Select Edge Device: Choose your Edge from dropdown

Step 3: Configure Adapter

• Adapter Type: Select MTConnect
• IP Address: Enter machine's IP address
• Port: Enter MTConnect agent port
  • 5000 (most common agent port)
  • 8082 (Haas agent port)
  • Note: 7878 is typically the adapter port, not the agent port
• Device Name: Leave blank unless multi-machine agent (see below)
• Click Test Connection

Step 4: Verify Connection

• Test should return "Connected" or success message
• If test fails:
  • Verify IP address is correct
  • Verify port is correct
  • Test endpoint in browser first
  • Check firewall settings
• Click Save when test succeeds

Step 5: Configure Data Collection

• Machine will appear in Machines list
• Initial data items collected automatically
• Configure part counting if needed
• Map additional data items as required

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Configuring Data Collection

Available Data Items

MTConnect provides rich data depending on machine implementation:

Status & Mode:

• Execution state (READY, ACTIVE, INTERRUPTED, STOPPED)
• Controller mode (AUTOMATIC, MANUAL, MDI, etc.)
• Emergency stop status
• Door state

Program Information:

• Program name
• Active block
• Line number

Production Metrics:

• Part count (varies by implementation)
• Cycle time
• Run time
• Idle time

Machine Parameters:

• Spindle speed (actual and override)
• Spindle load
• Feed rate (actual and override)
• Axis positions
• Axis loads

Alarms & Messages:

• Active alarms with codes
• Warning messages
• Operator messages

Tool Data (if available):

• Tool number
• Tool life
• Tool changes

Quality Data (CMMs):

• Measurement results
• Part program execution
• Inspection cycle data

Part Counting

Automatic Part Counting (Most Machines):

• MTConnect often provides part count automatically
• Counted based on program execution cycles
• No additional configuration needed
• Verify count is incrementing correctly in MachineMetrics

Manual Configuration (If Needed):

For Okuma (Common Variables):

If automatic counting doesn't work:

1. On Okuma Control:

   • Open MTConnect application
   • Navigate to "Device Configuration" page
   • Select common variable for part count (e.g., VC1)

2. In CNC Program:

   • Add common variable increment near end of program
   • Example: VC1=VC1+1 (increments by 1)
   • Example: VC1=VC1+2 (increments by 2 parts)

3. Notify MachineMetrics:

   • Contact support with variable number used
   • Configuration will be matched on our end

For Other Machines:

• Check MTConnect documentation for part count data item
• May be labeled "PartCount", "GoodCount", or similar
• Configure in MachineMetrics data mapping if not automatic

Multi-Machine Agents

Some MTConnect Agents report data for multiple machines over the same IP address and port.

Identifying Multi-Machine Setup:

• Browse to http://[IP]:[PORT]/probe
• Look for multiple <Device> entries in XML
• Each device will have a unique name

Configuration:

To collect data from a specific machine in a multi-machine agent:

1. In MachineMetrics, when adding the machine
2. Append device name to Connection Address
3. Format: [IP]:[PORT]/[DeviceName]
4. Example: 192.168.1.100:5000/Machine_1

In XML, look for:

<MTConnectDevices>
  <Devices>
    <Device name="Machine_1" ...>
    <Device name="Machine_2" ...>

Use the exact name from the XML, including underscores and capitalization.

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OEM-Specific Configurations

Mazak

Important: Only certain Mazak machines require MTConnect. See the Mazak Connectivity Guide to determine the correct connection method for your specific control type.

Connection Method Recommendation:

• Preview G, Smooth G, Smart controls: Require MTConnect (see below)
• Fusion 640, Matrix, Nexus, Preview 3, Smooth controls: Use Mazak Fusion Client (recommended unless MTConnect is already installed)
• If MTConnect is already installed on your Mazak: It's fine to continue using it

Supported Control Models:

Contact Mazak or refer to your machine documentation for MTConnect compatibility information.

General Guidelines:

• Smooth series (SmoothX, SmoothG, SmoothAi, etc.)
• Matrix series
• Controls made 2010 or newer
• Older controls may support MTConnect with software upgrade

Installation Process:

1. Check if Installed

   • Access Windows on control
   • Search for MTConnect folder
   • If found: proceed to configuration
   • If not found: contact Mazak

2. Request from Mazak

   • Mazak provides MTConnect on USB thumb drive
   • Each machine needs individual license
   • Order separate thumb drive for each machine
   • Includes installation files and instructions

3. Install from Thumb Drive

   • Follow Mazak-provided instructions
   • Installation includes:
     • MTConnect Adapter
     • MTConnect Agent
     • License file (machine-specific)
     • Configuration files

Network Configuration:

• Configure "PC IP Address" in Windows network settings
• DO NOT modify "NC IP Address" (internal machine communication)
• Default agent port: 5000 (or check MTConnect configuration)
• Default adapter port: 7878 (internal connection)

Service Management:

• Service name: "Mazak MTConnect" or similar
• Location: Control Panel → Services
• Ensure set to "Automatic" startup
• Verify "Running" status

Common Issues:

• Service fails to restart after power cycle
• See Troubleshooting section

Okuma

Supported Controls:

Control	THINC API	MTConnect	Notes
OSP 300	Current	Install from App Store	Best support, easy self-install
OSP 200	Update Required	Install from App Store	Contact Okuma dealer for API update
OSP 100-II	Update Required	Install from App Store	Contact Okuma dealer for API update
Other OSP 100	Not Supported	Not Available	Use I/O integration instead

Compatibility Verification:

• Use Scout tool at MyOkuma.com
• Full compatibility chart: MyOkuma MTConnect Page

Installation for OSP 300:

1. Access THINC App Store
2. Search for "MTConnect"
3. Download and install MTConnect Agent/Adapter
4. Follow on-screen instructions
5. Configuration happens automatically

Installation for OSP 200 / OSP 100-II:

1. First: Contact Okuma dealer for THINC API update
2. Then: Install MTConnect from THINC App Store
3. Both steps required for these controls

Enabling Monitoring Tags:

⚠️ Critical: This step is required even if MTConnect is installed.

1. Press CTRL + /// (access Windows)
2. Navigate: Programs → Okuma → Okuma MTConnect Adapter Application
3. Login:
   • Username: Administrator
   • Password: okuma+osp
4. Click Configuration tab
5. Click Tags Configuration button
6. Check "Enable Monitoring Tags"
7. Select data items to monitor (or select all)
8. Click Save & Close
9. Restart machine

Part Counting with Common Variables:

If part count doesn't increment automatically:

1. Open MTConnect application on Okuma
2. Go to "Device Configuration"
3. Select common variable (e.g., VC1)
4. In CNC program, add near the end:
   • VC1=VC1+1 (increment by 1)
   • VC1=VC1+2 (increment by 2)
5. Contact MachineMetrics with variable number for configuration match

Default Port: 5000

Accessing Windows: Press CTRL + ///

Hexagon CMMs

Supported Software:

• PC-DMIS 2019 R1 or later
• QUINDOS Version 8.1 or later

License Requirement:

• MTConnect Exporter license (purchased from Hexagon)
• Contact Hexagon support or reseller

Key Configuration:

• Default port: 5000
• Configure PC-DMIS/QUINDOS data path in utility
• Verify license is active before attempting connection

Data Available:

• CMM status (idle, measuring, alarm)
• Program execution state
• Cycle data
• Measurement events

Documentation:

• Hexagon Nexus Guide

Zeiss CMMs

Supported Software:

• CALYPSO 7.2 or newer
• PiWeb 8.x or newer

License Requirement:

• Zeiss MTConnect Data Interface license
• 60-day trial available
• Trial Download

Key Configuration:

• Default port: 5000 or 5001
• CALYPSO data path must be configured
• Service runs in background

Data Available:

• Machine status (Idle / Measuring / Alarm)
• Current part program name
• Measurement count
• Cycle time
• Operator ID (if configured)

Best Practices:

• Use static IP for CMM PC
• Schedule weekly service restart via Windows Task Scheduler
• Keep CALYPSO and MTConnect adapter versions in sync

Other MTConnect Machines

Generic Setup:

• Most MTConnect machines follow similar process
• Verify MTConnect is enabled
• Determine correct port (test with browser)
• Configure static IP
• Add to MachineMetrics using MTConnect adapter type

Common Ports:

• 5000 (most common agent port)
• 8082 (Haas agent port)
• Note: 7878 is typically an adapter port (internal)

If Unsure:

• Contact machine manufacturer
• Contact MachineMetrics support with machine details
• Test endpoint with browser first

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Troubleshooting

Connection Issues

Problem: Machine won't connect or test connection fails

Diagnostic Steps:

1. Verify Physical Connection

   • Ethernet cable securely connected
   • Link lights on network port active
   • Cable not damaged

2. Test Network Connectivity

   • Ping machine IP from Edge device or computer
   • If ping fails: network/routing problem
   • If ping succeeds: MTConnect or firewall issue

3. Test MTConnect Endpoint

   • Open browser on computer
   • Navigate to http://[machine-ip]:[port]/current
   • Try different ports: 5000, 7878, 8082
   • If XML appears: MTConnect is working, check MachineMetrics configuration
   • If no response: MTConnect not running or wrong port

4. Check Firewall

   • Windows Firewall on control may block MTConnect port
   • Temporarily disable to test (be sure to re-enable)
   • Or add firewall rule for MTConnect port
   • Common ports to allow: 5000, 7878, 8082

5. Verify MTConnect Service

   • Access Services on machine control
   • Find MTConnect service
   • Verify Status = "Running"
   • If stopped: Start the service

No Data Appearing

Problem: Connection succeeds but no data in MachineMetrics

Solutions:

1. Wait for Initial Sync

   • Allow 5-10 minutes for first data
   • MTConnect polls periodically
   • Refresh browser/app

2. Check Machine Status

   • Verify machine is powered on
   • Machine may need to be in certain mode
   • Run a program to generate data

3. Verify Endpoint Returns Data

   • Browse to http://[machine-ip]:[port]/current
   • Ensure XML contains actual values
   • If XML is empty or has no values: MTConnect configuration issue on machine

4. Check Data Mapping

   • Assets → Machines → [Your Machine] → Data Mapping
   • Verify data items are mapped
   • Look for unmapped items

5. Review Edge Logs

   • Settings → Edge Devices → Logs
   • Look for MTConnect errors or warnings

Mazak MTConnect Service Issues

Problem: Mazak MTConnect service won't stay running after reboot

This is a known issue with older Mazak MTConnect adapters.

Diagnostic Steps:

1. Access Windows on Mazak Control

   • Click Start menu
   • Type "Run" and press Enter
   • Type CMD and press Enter (opens command prompt)

2. Test MTConnect Locally

   • In command window, type: telnet localhost 7878
   • If you see streaming data: MTConnect is running, likely network issue
   • If telnet doesn't connect: Service not running

3. Check Service Status

   • Open Control Panel → Advanced Settings → Component Services
   • Find "MTConnect" or "Mazak MTConnect" in services list
   • Check if service is running
   • If not running: Right-click → Start

4. Verify Again

   • Return to command prompt
   • Retry telnet test: telnet localhost 7878
   • Should now see data stream

Permanent Fix:

• Contact Mazak dealer and request upgraded MTConnect adapter
• Newer software versions resolve auto-restart issues
• Upgrade recommended for production reliability

Okuma Issues

Problem: MTConnect installed but not reporting data

Check Monitoring Tags:

This is the most common Okuma issue.

1. Access Windows (CTRL + ///)
2. Open Okuma MTConnect Adapter Application
3. Login (Administrator / okuma+osp)
4. Configuration tab → Tags Configuration
5. Verify "Enable Monitoring Tags" is checked
6. If unchecked: Check it, Save & Close, restart machine

Problem: Part count not incrementing

⚠️ CRITICAL FIRST STEP: Verify Machine is Counting Parts

Before troubleshooting MachineMetrics or MTConnect configuration, verify the machine itself is incrementing its internal part counter.

MTConnect (and MachineMetrics) reads the machine's native part counter. If the machine isn't counting parts, MTConnect cannot report them. Without additional configuration, MachineMetrics relies entirely on the machine's internal part count signal provided by MTConnect.

Check Machine Part Counter:

1. Look at the machine's control screen
2. Find the part counter display (varies by machine/control)
3. Run a cycle
4. Verify the counter increments on the machine itself

If the machine counter is NOT incrementing:

• This is a machine configuration issue, not a MachineMetrics or MTConnect issue
• Machine is not configured to count parts
• For Okuma: See Okuma Part Counting section below

If the machine counter IS incrementing but MachineMetrics shows zero:

• This is a MachineMetrics or MTConnect adapter configuration issue
• Verify MTConnect adapter is reporting the part count
• Access MTConnect stream: http://[machine-ip]:[port]/current
• Look for <PartCount> or similar data item
• If present in MTConnect but not in MachineMetrics: Data mapping issue

Solution for Okuma Machines:

If Okuma part count not incrementing on machine itself, use Common Variables.

See Okuma Part Counting section for detailed setup.

Problem: THINC API too old

Solution:

• Contact Okuma dealer for THINC API update
• Required for OSP 200 and OSP 100-II
• Cannot self-install API update

Problem: Control not compatible

Solution:

• Use Scout tool to verify compatibility
• If not compatible: Use Digital I/O integration instead
• Contact MachineMetrics for alternative methods

Network Problems

Problem: Can access MTConnect locally but not from network

Cause: Firewall blocking MTConnect port

See Also: Network Requirements Guide for Edge device network and firewall requirements.

Solutions:

1. Check Windows Firewall

   • On machine control, open Windows Firewall
   • Check if MTConnect port (5000, 7878) is blocked
   • Add inbound rule to allow port

2. Test from Control First

   • On machine, open browser
   • Go to http://localhost:5000/current
   • If this works but external access doesn't: firewall

3. Create Firewall Rule

   • Windows Firewall → Advanced Settings → Inbound Rules
   • New Rule → Port → TCP → Specific Port (5000 or 7878)
   • Allow the connection
   • Apply to all profiles

4. Network Routing

   • Verify machine and Edge are on same subnet
   • Or proper routing is configured
   • Check with IT team if needed

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Best Practices

Network Configuration:

• Use static IP addresses for all machines
• Document IP addresses and ports
• Keep machine IPs in dedicated range
• Example: 192.168.1.100-199 for machines

MTConnect Service:

• Set services to "Automatic" startup
• Monitor service health periodically
• Keep MTConnect software updated
• Request latest versions from machine manufacturer

Data Quality:

• Verify part counting works correctly
• Map all relevant data items
• Test data accuracy against machine display
• Review data regularly for anomalies

Maintenance:

• Check service status weekly
• Monitor for adapter errors in Edge logs
• Keep machine control software updated
• Document any configuration changes

For CMMs:

• Use static IPs
• Schedule service restarts weekly (Task Scheduler)
• Keep measurement software and MTConnect versions in sync
• Validate XML output against MTConnect schema

Documentation:

• Record machine IPs and ports
• Document MTConnect version installed
• Keep notes on any special configurations
• Maintain list of common variable usage (Okuma)

Security:

• MTConnect uses HTTP (not HTTPS)
• Use dedicated machine network
• Limit access to MTConnect ports
• Don't expose MTConnect to public internet

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Additional Resources

MTConnect Institute:

• Official website: www.mtconnect.org
• Standards documentation
• Reference implementations
• Community forums

MTConnect GitHub:

• github.com/mtconnect
• Sample adapters for various machines
• Reference agent implementations
• Tools and utilities

Wikipedia:

• MTConnect Wikipedia Page
• Overview and history
• Industry adoption information

Articles:

• Modern Machine Shop - MTConnect Overview
• Control Design - MTConnect Guide

OEM Resources:

• MyOkuma MTConnect Page
• Hexagon MTConnect Guide
• Zeiss CMM Observer

MachineMetrics Resources:

• Knowledge Base: https://support.machinemetrics.com
• Machine Connectivity Overview
• Quick Start Checklist

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Getting Help

Before Contacting Support

Gather this information:

1. Machine Details

   • Make, model, serial number
   • Control type and version
   • MTConnect version (if known)

2. Network Configuration

   • Machine IP address
   • MTConnect port
   • Can you ping the machine?
   • Can you browse to MTConnect endpoint?

3. Test Results

   • Browser test result (XML output or error?)
   • Local test on control (if Windows-based)
   • Telnet test result (for Mazak)

4. Error Details

   • Exact error messages
   • Screenshots helpful
   • When problem started
   • What changed recently

Contact Options

MachineMetrics Support:

• Email: support@machinemetrics.com
• Include all information listed above
• Attach screenshots
• Describe troubleshooting steps attempted

Machine Manufacturer:

• For MTConnect installation files
• For software upgrades
• For control-specific questions
• For THINC API updates (Okuma)

Solution Delivery Manager (SDM):

• Configuration guidance
• Deployment planning
• Best practices

MTConnect Institute:

• Protocol questions
• Standards documentation
• Community support

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Ready to connect your MTConnect machine?

1. Verify MTConnect support
2. Enable MTConnect if needed
3. Configure network
4. Test endpoint in browser
5. Add machine in MachineMetrics
6. Verify data flow

Questions? Contact support@machinemetrics.com with your machine details.