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OPC-UA Connectivity Guide

Overview​

Siemens 840D Control

Siemens 840D sl CNC control panel. Siemens CNC controls (840D sl) use OPC-UA for connectivity, while 840D PL controls require BFC Gateway or I/O. Brother D-Series machines also use OPC-UA.

What is OPC-UA?​

OPC-UA (Open Platform Communications Unified Architecture) is a platform-independent, service-oriented architecture for secure and reliable exchange of data in industrial automation. It's an industry standard that ensures seamless information flow among devices from multiple vendors.

Key Characteristics:

  • Platform-independent (Windows, Linux, embedded systems)
  • Secure communication (encryption, authentication, certificates)
  • Rich data modeling capabilities
  • Service-oriented architecture
  • Maintained by the OPC Foundation

Important Note: Unlike MTConnect or FOCAS, OPC-UA does not standardize the meaning of data points. Each machine make, model, and configuration can have different data structures. This means OPC-UA connections require more initial configuration but provide great flexibility.

Why Use OPC-UA?​

When OPC-UA is the Best Choice:

  • Machine/controller natively supports OPC-UA
  • Need secure, encrypted communication
  • Connecting PLCs or automation equipment
  • Equipment doesn't support other protocols (FOCAS, MTConnect)
  • Connecting diverse equipment types (welders, presses, robots)

Advantages:

  • Industry-standard protocol
  • Secure by design
  • Rich data modeling
  • Platform-independent
  • Widely supported by automation vendors

Challenges:

  • Requires understanding of machine's data model
  • Need data map/tag list from manufacturer
  • More complex initial configuration
  • Certificate management may be required

Who This Guide is For​

This guide is for:

  • Engineers connecting OPC-UA-capable equipment
  • IT personnel configuring secure OPC-UA connections
  • Anyone connecting Siemens, Brother, or other OPC-UA machines
  • PLC programmers and automation specialists
  • System integrators working with diverse equipment

Compatible Machines​

Common OPC-UA Equipment​

CNC Machine Controls:

  • Siemens Sinumerik 828D / 840D SL (with OPC-UA license)
  • Brother D-Series CNC machines
  • Some FANUC robots
  • Various DMG MORI machines
  • Other modern CNC controls

Manufacturing Equipment:

  • Bystronic laser cutters and press brakes
  • Industrial robots (ABB, KUKA, Fanuc)
  • Automated assembly equipment
  • Process machinery

Automation & PLCs:

  • Siemens S7 PLCs
  • Allen-Bradley (via gateway)
  • Beckhoff controllers
  • B&R Automation
  • Many others

Third-Party OPC-UA Servers:

  • Kepware (common gateway/adapter)
  • MatrikonOPC
  • Softing OPC servers
  • Custom implementations

Checking for OPC-UA Support​

Check with Manufacturer:

  • Consult machine documentation
  • Contact machine tool builder support
  • Verify control version and options installed
  • Ask if OPC-UA license is required

Check on Machine:

  • Look for OPC-UA in control settings/menus
  • Check license page for OPC-UA option
  • Review control software version for OPC-UA support

Verify with Tools:

  • Use OPC-UA client software to attempt connection
  • Try connecting to opc.tcp://[machine-ip]:4840
  • Common ports: 4840, 4855, 49320, 56000 (varies by implementation)

Prerequisites​

Hardware Requirements​

  • Machine or equipment with OPC-UA server capability
  • MachineMetrics Edge device (deployed and activated)
  • Ethernet cable (CAT5/CAT6)
  • Network access between machine and Edge device

Software Requirements​

  • OPC-UA server enabled on machine/controller
  • OPC-UA license (if required by manufacturer)
  • OPC-UA client tool for browsing (UaExpert, opcua-commander, etc.)
  • Data map or tag list from machine manufacturer

Information Needed​

Before starting, gather:

  • Machine IP address
  • OPC-UA port number (typically 4840)
  • Username and password (if authentication required)
  • Security mode and policy (if applicable)
  • Data map/tag list showing:
    • Node IDs for relevant data
    • What each tag represents (status, part count, etc.)
    • Data types and units
  • Certificate requirements (if any)

Understanding OPC-UA​

Architecture​

OPC-UA uses a client-server model:

Machine/Controller (OPC-UA Server)
     ↓
Network (TCP/IP)
     ↓
MachineMetrics Edge Device (OPC-UA Client)
     ↓
MachineMetrics Cloud

Components:

  • Server: Runs on machine/controller, exposes data
  • Client: MachineMetrics Edge device, reads data
  • Address Space: Hierarchical structure of available data nodes
  • Nodes: Individual data points with unique identifiers

Data Structure​

OPC-UA data is organized in a tree-like address space with nodes.

Node ID Format:

  • ns=2;s=/Channel/State/progStatus (string identifier)
  • ns=3;i=1001 (integer identifier)
  • ns=4;g=A7B3... (GUID identifier)

Where:

  • ns = namespace index
  • s = string identifier
  • i = integer identifier
  • g = GUID identifier

Data Types:

Simple Types:

  • String, Boolean, DateTime
  • Double, Float, Int32, Int64
  • Guid, LocalizedString

Complex Types:

  • Objects (structures with properties)
  • Enumerations (predefined value sets)
  • Arrays (ordered collections)

Example:

Node: ns=2;s=/Channel/State
  ↳ Property: progStatus (Int32)
  ↳ Property: opMode (String)
  ↳ Property: actParts (Int32)

Security Modes​

OPC-UA supports multiple security configurations:

ModeDescriptionUse Case
NoneNo encryption, no authenticationTesting, internal networks only
SignData is signed (integrity)Standard security
SignAndEncryptData signed and encryptedHigh security environments

Common Security Policies:

  • None - No security
  • Basic128Rsa15 - Older security standard
  • Basic256 - Common standard
  • Basic256Sha256 - Modern, recommended standard

Browsing OPC-UA Servers​

Before configuring MachineMetrics, you need to browse the OPC-UA server to find relevant data nodes.

Option 1: GUI Client (Recommended for most users)

UaExpert (Free from OPC Foundation):

Steps:

  1. Install UaExpert
  2. Add new server connection
  3. Enter endpoint URL: opc.tcp://[machine-ip]:[port]
  4. Connect (handle certificates if prompted)
  5. Browse address space to find data nodes
  6. Note node IDs for relevant data

Option 2: Command Line Client

uals (Python OPC-UA tools):

Usage:

uals -u opc.tcp://[address]:[port] -i [namespace_id] -d [tree_depth]

opcua-commander (Interactive terminal client):

Physical Connection​

Step 1: Connect Ethernet Cable

  • Plug cable into machine's Ethernet port
  • For Siemens CNC: Typically X130 (company network port)
  • For Brother: Standard network port on control
  • Verify link lights

🔴 CRITICAL WARNING for Siemens CNC Machines:

  • Always check your machine documentation for the correct port address
  • Port designation varies by machine tool builder (X130 is common, but not universal)
  • These machines have complex internal networks and PROFIBUS
  • Connecting to the wrong port can BRICK the machine
  • NEVER connect to system network ports (192.168.214.x or 192.168.215.x ranges)
  • When in doubt, contact your machine tool builder

Step 2: Configure Network

  • Set static IP on machine (recommended)
  • Document IP address, subnet, gateway
  • Ensure machine and Edge device are on same subnet or properly routed

Step 3: Test Connectivity

  • Ping machine IP from Edge or computer
  • Verify response
  • Check firewall allows OPC-UA port

Enabling OPC-UA on Your Machine​

Generic OPC-UA Setup​

For machines with OPC-UA capability:

  1. Verify License

    • Check if OPC-UA option is licensed
    • Purchase/install license if needed
    • Verify license is activated

  2. Enable OPC-UA Server

    • Access machine settings/configuration
    • Look for OPC-UA, network, or communication settings
    • Enable OPC-UA server function

  3. Configure Port

    • Default: 4840
    • Some implementations use different ports
    • Note the port for later

  4. Set Authentication

    • Create username and password (if required)
    • Or enable anonymous access (testing only)
    • Document credentials

  5. Configure Security

    • Select security mode (None, Sign, SignAndEncrypt)
    • Select security policy (None, Basic256, Basic256Sha256)
    • Balance security needs with compatibility

  6. Restart/Reboot

    • Changes typically require restart
    • Follow manufacturer instructions

Siemens 828/840D SL Setup​

Prerequisites:

  • SINUMERIK Operate installed
  • OPC-UA license: 6FC5800-0AP67-0YBO (purchased from Siemens)
  • Manufacturer access level password
  • Static IP from your IT team

Compatibility:

CNC Software VersionOPC-UA Version Supported
4.5V2.2 and V3.0 SP1
4.07 SP2-SP5V2.2 and V3.0 SP1
4.08 SP2-SP3V2.2 and V3.0 SP1
4.92 and 4.92 HF2V3.0 SP1

Step 1: Enable Manufacturer Access

  1. Select Startup area (🔧 Setup icon)
  2. Press Password → Set password
  3. Enter manufacturer password: SUNRISE
  4. Press OK
  5. Status bar should show: "Access level: Manufacturer"

Note: If rejected, the OEM may have changed the default password. Contact machine builder.

Step 2: Set License

  1. Go to Startup
  2. Press Licenses soft key
  3. Navigate to Access MyMachine / OPC UA
  4. Check the box under Set
  5. If license not available: Purchase from Siemens

Step 3: Set Company Network IP (X130 Port)

🔴 CRITICAL WARNING:

  • X130 is the most common port, but always verify with your machine documentation
  • Different machine tool builders use different port designations
  • These machines have complex internal networks and PROFIBUS
  • Connecting to the wrong port can BRICK your machine
  • NEVER modify system network (192.168.214.x or 192.168.215.x ranges)
  • When in doubt, contact your machine tool builder before proceeding
  1. Select Diagnostics
  2. Press menu forward key → Choose Bus TCP/IP
  3. Select TCP/IP diagnostics → TCP/IP config
  4. Select interface X130 (or your machine's designated company network port - verify in documentation)
  5. Press Change
  6. Set Address Type = Manual (for static IP)
  7. Enter network settings:
    • IP Address: Assigned by IT team
    • Subnet Mask: From IT team
    • Gateway: Only if needed for routing outside subnet
  8. Press OK
  9. Restart the control (mandatory for changes to take effect)

Physical Port Location:

  • On SINUMERIK 828D: Typically rear-panel Ethernet port labeled X130
  • Verify port designation in your machine documentation
  • Use shielded CAT5e/CAT6 cable
  • Connect directly to company network switch

Step 4: Configure OPC-UA Server

  1. In Startup area, navigate to: Network → OPC UA → Setting → Change

  2. Connection Settings:

    • Verify Company network is selected
    • Confirm IP address (your Company IP)
    • TCP Port: 4840 (default, leave unchanged)

  3. Authentication:

    • Admin User: Create username (e.g., OpcUaClient)
    • Password: Set secure password (needed for MachineMetrics connection)
    • Allow anonymous access: Uncheck (for security)
    • Accept certificates automatically: Check only for initial testing

  4. Activation:

    • Check Activate OPC UA

  5. Press OK → Save PCU settings

  6. Restart OPERATE for changes to take effect

Step 5: Verify Connectivity

  1. From PC on same network: ping [machine-ip]
  2. In Startup → Network → OPC UA → Status
  3. Confirm server lists Company IP (e.g., 10.1.0.46:4840)
  4. Should show Status: OK

Step 6: Accept Certificates

When MachineMetrics Edge first connects:

  1. Go to Startup → Network → OPC UA → Certificates
  2. Under "Pending Certificates", select the client certificate
  3. Press Accept
  4. Status page should show connected clients

Step 7: Return to Normal Access Level

  1. Go to Startup → Password → Set password
  2. Press Cancel or enter user-level password
  3. Status bar should return to "Access level: User"

Additional Resources:

Brother D-Series Setup​

Step 1: Access Communication Menu

  1. From main screen, press DATABANK soft key
  2. Select 7. Communication parameter
  3. Navigate to Ethernet/FTP settings

Step 2: Configure Static IP

⚠️ Important: Brother controls use special numeric format for IP addresses.

  1. 0202 - Use DHCP → Set to No
  2. 0203 - IP address → Enter IP as 12-digit number
    • Standard format: 172.22.3.34
    • Brother format: 172022003034 (no dots!)
    • Pad each octet to 3 digits
  3. 0204 - Mask bit → Typically 255.255.255.0

Step 3: Configure Network Access

  1. 0004 - Display slave command alarm → Set to No
  2. 0216 - Restrict Ethernet access → Set to No

Step 4: Enable OPC-UA

Navigate to final Ethernet/FTP menu screen:

  1. 0235 - OPC UA server function → Set to Valid
  2. 0236 - Security communication for client → Set to 2: Type2
  3. 0237 - OPC UA security communication → Set security level:
    • 0: No - No username/password (simplest)
    • 1-5 - RSA/AES encryption with authentication

Step 5: Save Settings

  1. Press Save and end (bottom left)
  2. Or use Overwrite save to continue editing

⚠️ Critical: If you don't save, all changes are lost on shutdown/reboot.

Step 6: Verify Connectivity

  1. Press MONITR soft key
  2. Select 3. Communication monitor
  3. Look for Ethernet (OPC UA) in Port column
  4. Message column should show:
    • Sending completed
    • Data sent
    • Output request received

Step 7: Check Ethernet Information

  1. In MONITR menu, select Ethernet information
  2. Verify displays:
    • IP Address (as configured)
    • Subnet Mask
    • Gateway
    • MAC Address
    • DHCP status

Connection String for MachineMetrics:

opc.tcp://[ip-address]:4840

Example: opc.tcp://10.103.112.62:4840

Sample Script: Brother OPC-UA Sample

Bystronic Setup​

Step 1: Enable OPC-UA

  1. Navigate to Modules → Administration → Advanced Settings
  2. Find OPC-UA setting
  3. Enable OPC-UA server

Step 2: Open Firewall Ports

Port 56000 (both TCP and UDP) must be open on both:

  • Brake panel PC
  • Server

Note: For network-level firewall configuration and Edge device requirements, see the Network Requirements Guide.

Creating Firewall Rules:

For TCP Port:

  1. Open Control Panel on machine/server
  2. System and Security → Windows Defender Firewall
  3. Advanced Settings → Inbound Rules
  4. Actions (right side) → New Rule
  5. Select Port → Next
  6. Select TCP → Enter 56000 for Specific Local Port → Next
  7. Select Allow the connection → Next
  8. Select Domain, Private, Public → Next
  9. Enter name: Bystronic56000TCPPort → Finish

For UDP Port:

  1. Actions → New Rule
  2. Select Port → Next
  3. Select UDP → Enter 56000 → Next
  4. Allow the connection → Next
  5. Select all profiles → Next
  6. Enter name: Bystronic56000UDPPort → Finish

Step 3: Reboot

Reboot the entire machine (not just the PC) for changes to take effect.

Connection Port: 56000

Adding the Machine in MachineMetrics​

Once OPC-UA is enabled and network is configured:

Step 1: Browse OPC-UA Server First

Before adding in MachineMetrics, use an OPC-UA client to:

  • Verify you can connect to the server
  • Browse available data nodes
  • Document node IDs for relevant data
  • Create data map/tag list

Step 2: Log into MachineMetrics

  • Navigate to Assets → Machines
  • Click Add Machine

Step 3: Enter Machine Details

  • Machine Name: Descriptive name
  • Make: Manufacturer
  • Model: Machine model
  • Select Edge Device: Choose your Edge

Step 4: Configure OPC-UA Adapter

  • Adapter Type: Select OPC-UA
  • Connection String: opc.tcp://[ip-address]:[port]
    • Example: opc.tcp://192.168.1.100:4840
  • Username: If authentication required
  • Password: If authentication required
  • Security Mode: None, Sign, or SignAndEncrypt
  • Security Policy: None, Basic256, Basic256Sha256
  • Click Test Connection

Step 5: Verify Connection

  • Test should return success
  • If fails: Check connection string, credentials, firewall
  • Click Save when successful

Step 6: Configure Adapter Script

This is where you define which data nodes to collect.

Configuring Data Collection​

Available Data Items​

Data available through OPC-UA varies widely by implementation. Common items include:

Machine Status:

  • Execution state (running, idle, stopped)
  • Controller mode (AUTO, MDI, MANUAL)
  • Alarm status

Program Information:

  • Program name
  • Line number
  • Block counter

Production Metrics:

  • Part count (various methods)
  • Cycle time
  • Run time

Machine Parameters:

  • Spindle speed and load
  • Feed rate and override
  • Axis positions
  • Tool number

Alarms & Diagnostics:

  • Active alarms with codes
  • Alarm history
  • Diagnostic values

Custom Data:

  • Process parameters
  • Quality measurements
  • Automation status
  • Equipment-specific values

OPC-UA Adapter Scripts​

MachineMetrics uses YAML configuration to map OPC-UA data to our standard model.

Script Structure:

version: 2
username: your-username  # If required
password: your-password  # If required
security-mode: Sign  # None, Sign, or SignAndEncrypt
security-policy: Basic256Sha256  # or Basic256, Basic128Rsa15, None

tags:
  # Define data nodes to monitor
  
variables:
  # Transform and model data
  
data-items:
  # Specify which items to send to MachineMetrics

Tags Configuration​

Tags define references to specific nodes in the OPC-UA address space.

Simple Tag (Direct Value):

tags:
  spindle-speed:
    path: ns=2;s=/Nck/Spindle/actSpeed
  program-name:
    path: ns=2;s=/Channel/ProgramInfo/progName

Complex Type Tag (Object with Properties):

tags:
  part-quantity:
    path: ns=2;s=/Laser/CurrentPlan
    property: partQuantity

This retrieves the partQuantity property from the CurrentPlan object.

Variables and Transformations​

Variables transform tag values into MachineMetrics standard model.

Pass-Through (No Transformation):

variables:
  spindle-rpm:
    - source: spindle-speed

State Transformation (Conditional Logic):

variables:
  execution:
    - source: prog-status
    - state:
      - INTERRUPTED: this == 1
      - STOPPED: this == 2 or this == 5
      - ACTIVE: this == 3 or this == 4
      - READY: true  # Fallback

Count on Value Change:

variables:
  part-count:
    - source: part-quantity
    - value-change
    - count

Mathematical Operations:

variables:
  execution:
    - source: laser-power
    - state:
      - ACTIVE: this > 0
      - READY: true

Data Mapping​

After adapter script is configured, map data items in MachineMetrics:

Step 1: Edit Machine

  1. Assets → Machines → [Your Machine]
  2. Go to Data Mapping tab
  3. Click Refresh List to see new items

Step 2: Map Each Data Item

For each data item from your script:

  • Select Type (e.g., "Part Count", "Sample", "Event")
  • Select Subtype (e.g., "Actual", "Speed", "Status")
  • Assign Component (e.g., "Spindle", "Controller")
  • Add Display Name (human-readable description)

Step 3: Save Mappings

  • Review all mappings
  • Click Save Changes
  • Data will now flow to MachineMetrics dashboards and reports

Sample Configurations​

Siemens 840D Sample Script​

version: 2
username: OpcUaClient
password: YourSecurePassword
security-mode: Sign
security-policy: Basic256Sha256

tags:
  tool-group:
    path: ns=2;s=/Channel/State/actToolIdent
  tool-num:
    path: ns=2;s=/Channel/State/actTNumber
  line-number:
    path: ns=2;s=/Channel/ProgramInfo/actLineNumber
  spindle-load:
    path: ns=2;s=/Nck/Spindle/driveLoad
  prog-status:
    path: ns=2;s=/Channel/State/progStatus
  controller-op-mode:
    path: ns=2;s=/Bag/State/opMode
  spindle-speed:
    path: ns=2;s=/Nck/LogicalSpindle/actSpeed
  last-alarm-number:
    path: ns=2;s=/Nck/LastAlarm/alarmNo
  feed-rate:
    path: ns=2;s=/Channel/MachineAxis/actFeedRate
  prog-name:
    path: ns=2;s=/Channel/ProgramInfo/progName
  act-parts:
    path: ns=2;s=/Channel/State/actParts
  feedrate-ovr:
    path: ns=2;s=/Channel/MachineAxis/feedRateOvr

variables:
  execution:
    - source: prog-status
    - state:
      - INTERRUPTED: this == 1
      - STOPPED: this == 2 or this == 5
      - ACTIVE: this == 3 or this == 4
      - READY: true
  controller-mode:
    - source: controller-op-mode
    - state:
      - MANUAL: this == 0
      - MANUAL_DATA_INPUT: this == 1
      - AUTOMATIC: this == 2

data-items:
  - execution
  - controller-mode
  - spindle-speed
  - spindle-load
  - feed-rate
  - feedrate-ovr
  - last-alarm-number
  - line-number
  - tool-group
  - tool-num
  - prog-name
  - act-parts

Note: This script is valid for Siemens 828/840D SL controls. Node paths may differ for other machines.

Brother Sample Script​

Sample configuration for Brother D-Series CNC machines available from MachineMetrics support.

Connection:

  • Port: 4840
  • Security: Typically Type2
  • Format IP correctly in control (12-digit numeric)

Generic Laser Cutter Script​

version: 2
tags:
  part-quantity:
    path: ns=2;s=Laser.CurrentPlan
    property: partQuantity
  laser-power:
    path: ns=2;s=Laser.CurrentLaserPower
  cut-state:
    path: ns=2;s=Laser.CurrentCutState

variables:
  part-count:
    - source: part-quantity
    - value-change
    - count
  execution:
    - source: laser-power
    - state:
      - ACTIVE: this > 0
      - READY: true

data-items:
  - execution
  - part-count
  - part-quantity
  - cut-state

Explanation:

  • part-count: Counts each time part-quantity changes
  • execution: ACTIVE when laser power > 0, otherwise READY
  • Direct pass-through for part-quantity and cut-state

Certificate Management​

Understanding Certificates​

OPC-UA uses X.509 certificates for security:

  • Server Certificate: Identifies the machine/server
  • Client Certificate: Identifies MachineMetrics Edge
  • Both sides must trust each other's certificates

Accepting Certificates​

On Siemens Controls:

  1. Startup → Network → OPC UA → Certificates
  2. Pending certificates appear when client first connects
  3. Select client certificate → Accept
  4. MachineMetrics Edge must also trust server certificate (usually automatic)

On Other Controls:

  • Process varies by manufacturer
  • Check control documentation
  • May auto-accept or require manual approval

Testing During Setup:

  • Can enable "Accept certificates automatically" initially
  • Disable after confirming connection works
  • For production, use proper certificate validation

Certificate Errors:

  • Usually appear as connection failures
  • Check that certificates are accepted on both sides
  • Verify certificate hasn't expired
  • Check system time/date on both devices

OEM-Specific Notes​

Siemens Sinumerik 828/840D SL​

Key Points:

  • Requires OPC-UA license purchase
  • Typically uses X130 port (company network) - but always verify with your machine documentation
  • CRITICAL: Different machine tool builders use different port designations
  • Connecting to the wrong port can brick the machine - these machines have complex internal networks and PROFIBUS
  • Never modify system network (192.168.214.x / 215.x)
  • Default manufacturer password: SUNRISE
  • Port: 4840
  • Requires restart after configuration

Version-Specific Guides:

  • Different Operate versions have slightly different menus
  • See Additional Resources section for version-specific PDFs
  • Always verify your Operate version first

Finding Operate Version:

  1. Startup area → Version or Version display soft key
  2. Look for "SINUMERIK Operate Version" (e.g., 4.7 SP2 HF3)

Brother D-Series CNC​

Key Points:

  • IP address format is 12-digit numeric (not standard dot notation)
  • Port: 4840
  • Security Type2 common
  • Must save settings or they're lost
  • Communication monitor confirms OPC-UA activity

IP Format Examples:

  • 172.22.3.34 → Enter as 172022003034
  • 10.1.50.200 → Enter as 010001050200
  • Pad each octet to exactly 3 digits

Verification:

  • Use Communication monitor to verify OPC-UA activity
  • Ethernet information screen confirms IP settings

Bystronic​

Key Points:

  • Port: 56000 (not standard 4840)
  • Requires both TCP and UDP firewall rules
  • Must reboot entire machine (not just PC)
  • Enable in Modules → Administration → Advanced Settings

Unique Port:

  • Bystronic uses port 56000 instead of standard 4840
  • Must open both TCP and UDP for this port

Fanuc Robots​

Key Points:

  • Fanuc robots support OPC-UA
  • Typically port 4880
  • Requires network configuration on robot controller
  • Data structure varies by robot model

Contact:

  • Fanuc robot support for specific configuration
  • MachineMetrics support for adapter script assistance

Other OPC-UA Equipment​

Generic Process:

  1. Verify OPC-UA is licensed and enabled
  2. Determine port number
  3. Get data map from manufacturer
  4. Use OPC-UA client to browse server
  5. Create adapter script based on relevant nodes
  6. Work with MachineMetrics support for script development

Troubleshooting​

Connection Issues​

Problem: Can't connect to OPC-UA server

Diagnostic Steps:

  1. Verify Network Connectivity

    • Ping machine IP from Edge or computer
    • If ping fails: network problem
    • If ping succeeds: OPC-UA configuration issue

  2. Test with OPC-UA Client

    • Use UaExpert or similar tool
    • Try connecting from a computer on same network
    • Try endpoint: opc.tcp://[machine-ip]:[port]
    • If client can't connect: OPC-UA not properly enabled

  3. Verify Port Number

    • Common ports: 4840, 56000 (Bystronic), 49320 (Kepware), 4880 (Fanuc robots)
    • Check machine documentation
    • Try different ports if unsure

  4. Check Firewall

    • Windows Firewall on control may block OPC-UA port
    • Temporarily disable to test (re-enable after)
    • Or create firewall rule for OPC-UA port

  5. Verify OPC-UA Service

    • Check that OPC-UA server is enabled on machine
    • May be in license settings, network settings, or services

Authentication Failures​

Problem: Connection fails with authentication error

Solutions:

  1. Verify Credentials

    • Double-check username and password
    • Case-sensitive
    • No extra spaces

  2. Check Authentication Settings

    • Verify username/password is configured on machine
    • Some machines require creating OPC-UA user account
    • Check if anonymous access is enabled (for testing)

  3. Security Mode Mismatch

    • Verify security mode matches machine configuration
    • Try None, Sign, then SignAndEncrypt
    • Must match what machine expects

  4. Security Policy Mismatch

    • Verify policy matches machine capability
    • Try None, then Basic256, then Basic256Sha256
    • Older equipment may only support Basic128Rsa15

Certificate Errors​

Problem: Certificate validation failures

Solutions:

  1. Accept Certificates

    • On machine: Accept MachineMetrics Edge certificate
    • On Edge: Usually accepts automatically
    • Check pending certificates on machine

  2. Check System Time

    • Certificates have validity periods
    • If machine or Edge time is wrong, certificates fail
    • Sync time via NTP

  3. Regenerate Certificates

    • May need to clear and regenerate
    • Contact MachineMetrics support for assistance

  4. Temporary: Disable Certificate Validation

    • For testing only
    • Enable "Accept certificates automatically"
    • Properly configure for production

No Data Appearing​

Problem: Connected but no data in MachineMetrics

Solutions:

  1. Check Adapter Script

    • Verify YAML syntax is correct
    • Ensure tags reference valid node IDs
    • Test node IDs in OPC-UA client first

  2. Verify Data Mapping

    • Assets → Machines → Data Mapping
    • Ensure data items from script are mapped
    • Check for unmapped items

Part Count Issues​

Problem: Part counts not incrementing or incorrect

⚠️ CRITICAL FIRST STEP: Verify Machine is Counting Parts

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

MachineMetrics reads the machine's native part counter via OPC-UA. If the machine isn't counting parts, MachineMetrics cannot report them. Without additional scripting or configuration, MachineMetrics relies entirely on the machine's internal part count signal exposed via OPC-UA.

Check Machine Part Counter:

  1. Look at the machine's control screen or HMI
  2. Find the part counter display (varies by machine/OEM)
  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 issue
  • Machine is not configured to count parts
  • Consult machine manual or OEM for part counting configuration
  • May require enabling part counting in machine settings

If the machine counter IS incrementing but MachineMetrics shows zero:

  • This is a MachineMetrics or OPC-UA configuration issue
  • Continue to diagnostic steps below

Diagnostic Steps:

  1. Verify Part Count Tag in OPC-UA

    • Use OPC-UA client (UaExpert) to browse server
    • Find part count tag/node ID
    • Watch tag value while running machine
    • If tag doesn't increment in OPC-UA client: Machine not exposing part count

  2. Check Adapter Script

    • Verify part count tag is referenced in YAML script
    • Ensure node ID is correct (copy from OPC-UA client)
    • Verify data-items includes part count variable

  3. Check Data Mapping

    • Assets → Machines → Data Mapping
    • Ensure part count data item is mapped
    • Type should be "Part Count"

  4. Test with OPC-UA Client

    • Connect to machine with UaExpert
    • Monitor part count tag in real-time
    • Run a cycle on machine
    • If tag increments in UaExpert but not MachineMetrics: Configuration issue
    • If tag doesn't increment in UaExpert: Machine not counting parts

Common OEM-Specific Notes:

  • Bystronic: Look for Production.PartCounter or similar in OPC-UA tree
  • Siemens: Check DB (Data Block) for part count variable
  • Fanuc Robots: May require program command to increment counter (e.g., R[1]=R[1]+1)

  1. Check Machine Status

    • Machine may need to be running to generate some data
    • Verify OPC-UA server is active

  2. Review Edge Logs

    • Settings → Edge Devices → Logs
    • Look for OPC-UA errors
    • Check for node ID errors or parsing issues

  3. Test with Simple Script First

    • Start with minimal configuration
    • Add one or two tags
    • Verify those work before adding more

Firewall Issues​

Problem: Can connect locally but not from network

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

Solutions:

  1. Windows Firewall (On Machine)

    • Open Windows Firewall settings
    • Create inbound rule for OPC-UA port
    • Allow TCP and UDP
    • Apply to all profiles

  2. Network Firewall

    • Work with IT team
    • Ensure OPC-UA port allowed between machine and Edge
    • May need exception for specific IP addresses

  3. Test Locally First

    • On machine control, use OPC-UA client
    • Connect to opc.tcp://localhost:[port]
    • If this works but remote doesn't: firewall

Best Practices​

Planning:

  • Browse OPC-UA server before configuration
  • Create comprehensive data map with manufacturer's help
  • Start with essential data items, add more later
  • Document all node IDs and their meanings

Security:

  • Use strong passwords for OPC-UA accounts
  • Use Sign or SignAndEncrypt security mode
  • Properly manage certificates
  • Don't use anonymous access in production
  • Use dedicated network for machine connectivity

Network:

  • Use static IP addresses
  • Document IP, port, and credentials
  • Test connectivity before full configuration
  • Keep machine firewall rules documented

Configuration:

  • Start with simple adapter script
  • Test incrementally (add tags one at a time if issues)
  • Validate data accuracy against machine display
  • Keep backup of working configurations

Data Mapping:

  • Use descriptive display names
  • Map all relevant data items
  • Assign proper types and subtypes
  • Review mappings for accuracy

Maintenance:

  • Monitor for connection errors in Edge logs
  • Keep OPC-UA server software updated
  • Review certificate expiration dates
  • Document any configuration changes made

Working with Manufacturers:

  • Request complete data map/node list
  • Ask for recommended node IDs for status, count, etc.
  • Get clarification on data types and units
  • Request sample configurations if available

Additional Resources​

OPC Foundation:

  • Official website: opcfoundation.org
  • OPC-UA specification
  • Client tool downloads
  • Training and certification

OPC-UA Client Tools:

Standards:

  • UMATI (Universal Machine Tool Interface)
  • MTConnect OPC-UA Companion Specification
  • Industry-specific OPC-UA standards (emerging)

MachineMetrics Resources:

Getting Help​

Before Contacting Support​

Gather this information:

  1. Machine Details

    • Make, model, serial number
    • Control type and version
    • OPC-UA license status

  2. Network Configuration

    • Machine IP address and port
    • Connection string used
    • Can you ping the machine?

  3. OPC-UA Browsing Results

    • Can you connect with UaExpert or other client?
    • What data nodes are available?
    • Node ID examples

  4. Current Configuration

    • Adapter script (YAML)
    • Data mapping configuration
    • Any error messages from Edge logs

  5. Authentication & Security

    • Security mode and policy used
    • Username (don't include password in emails)
    • Certificate status

Contact Options​

MachineMetrics Support:

Machine Manufacturer:

  • For OPC-UA license/enablement
  • For data map and node ID documentation
  • For control-specific configuration
  • For software updates

Solution Delivery Manager (SDM):

  • For deployment planning
  • For adapter script development assistance
  • For best practices and optimization

OPC Foundation:

  • For protocol questions
  • For client tool support
  • For standards documentation

Ready to connect your OPC-UA machine?

  1. Verify OPC-UA support and licensing
  2. Browse OPC-UA server to identify data nodes
  3. Configure network and enable OPC-UA
  4. Create adapter script for your machine
  5. Add machine in MachineMetrics
  6. Map data items
  7. Verify data flow

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

Need adapter script help? MachineMetrics support can assist with creating custom OPC-UA adapter scripts based on your machine's data structure.