Installing Amper's aggregator

What you'll need

Gateway
(“GW” on device)
Aggregator
(“AG” on device with green screw post connector on top)
CAT5 cable
Power supply cable
Tools
  • Small screwdriver, wire strippers, wire
  • Tools to open machine panel and insert new wires into machine output or input terminal blocks
  • A machine schematic or wiring diagram
Recommended skills
  • Opening up the power and/or control panels on the machine.
  • Determining the best signal or sensor output available that corresponds to a machine cycle.
  • Reading machine schematics and identifying signal wires inside the machine.

What are you measuring with your digital aggregator?

Installation depends on what you'll be measuring. Choose your metric below to go to the right guide.
Utilization
Cycle counts
Both

Aggregator for utilization

INSTALL THE AGGREGATOR

Steps at a glance

This part of the installation will require you to connect the aggregator and oftentimes to study your machine schematic to identify the utilization signal you'll be working with.

DOWNLOAD DATA SHEET

Connect the aggregator

Mount aggregator

Place the aggregator inside the machine’s power panel (or outside panel if using an external sensor).

Connect aggregator to gateway or existing device

If an existing aggregator is installed: Connect the new aggregator via CAT5 cable to the existing device's second CAT5 jack.

If there is no existing device: Connect the aggregator to the gateway via CAT5 cable using either CAT5 jack.

Verify connection

Check for a solid blue LED light in the lower left corner of the digital aggregator.

This indicates power and successful gateway connection.

    Identify signals and outputs

    Choose a suitable signal for utilization
    • A signal that remains in the “on” state for the entire cycle (e.g. “chuck clamp closed” signal).
    • A signal that changes states 1+ times during production (e.g. the control signal for a solenoid on a machine with pneumatic or hydraulic components that fire multiple times per cycle).
    • An external sensor (e.g. proximity switch, light curtain, or line beam sensor) if your machine does not have a suitable signal to represent ongoing production.
    See the data sheet for wiring diagrams on common ways to connect a signal.
    Locate the signal in your machine
    • Go to the page that lists “Machine I/O” or “Outputs” in your machine schematic or wiring diagram.
    • Find the name corresponding to your chosen signal.
    • Note the output or wire label code and the module label code.
    • Use the codes to locate the module and the output or signal wire in your machine panel.
    Identify nearby power outputs
    It is usually best to find existing 24V and 0V or ground outputs on the same module as the selected signal.
    • Identify a +24V (or +12V if applicable) power output on your machine.
    • Identify a 0V ground output (usually different than the chassis or earth ground).
    • Refer to the same page on the schematic along with the page for the machine DC power supply to confirm the appropriate outputs if you are not sure.
    • Place the aggregator near the relevant outputs if you haven’t already done so.

    Connect to your machine

    Connect to power
    • Cut two insulated wires and strip the ends. They should be long enough to connect the power outputs to the aggregator.
    • Use one wire to connect the +24Vdc output to the corresponding screw post input on the aggregator (first, outermost screw post with red label).
    • Use the other wire to connect the 0Vdc to the corresponding screw post input on the aggregator (second screw post with black label).
    • If successfully connected, the rightmost LED (labeled “PWR”) should light up when the machine is powered on and +24V power is available.
    Connect to the chosen signal
    The signal will be connected with a single wire.
    • If capturing an existing signal, simply slip the new wire into the output alongside the existing one.
      Tight fit? You may need to remove the existing wire, twist the new one around it, and then reinsert it.
    • If using an empty output, insert the new wire as normal. The wire can then be screwed into the digital aggregator’s input.

    Aggregator for cycle counts

    INSTALL THE AGGREGATOR

    Steps at a glance

    This part of the installation will require you to connect the aggregator and oftentimes to study your machine schematic to identify the utilization signal you'll be working with.

    Download datasheet

    Connect the aggregator

    Mount aggregator

    Place the aggregator inside the machine’s power panel (or outside panel if using an external sensor).

    Connect aggregator to gateway or existing device

    If an existing aggregator is installed: Connect the new aggregator via CAT5 cable to the existing device's second CAT5 jack.

    If there is no existing device: Connect the aggregator to the gateway via CAT5 cable using either jack.

    Verify connection

      Check for a solid blue LED light in the lower left corner of the digital aggregator.

      This indicates power and successful gateway connection.

      Identify signals and outputs

      First you must identify which signal you will be working with. Then, you’ll locate that signal in your machine’s power panel and identify the nearest power outputs.

      Choose a suitable signal for for cycle counting

      It’s critical to choose a signal that changes back and forth exactly once per cycle.

      • M-Code: Program a spare M-Code output (if available) into your end-of-program macro (e.g. an M30) to momentarily turn the output on when the count should be registered.
      • Other high-accuracy options include existing signals in your machine:
        - Part presence or proximity sensor output
        - Bar feeder control
        - Chuck clamp closed
        - Solenoid control (for pneumatic or hydraulic actions that happen once per cycle)
        - Control for any other discrete operations that happen once per cycle
      • If your machine does not have a suitable signal that can represent ongoing production, then installing an external sensor may be the best option (e.g. proximity switch, light curtain, or line beam sensor).
      See the data sheet for wiring diagrams on common ways to connect a signal.
      Locate the signal in your machine
      ‍
      • Go to the page that lists “Machine I/O” or “Outputs” in your machine schematic or wiring diagram.
      • Find the name corresponding to your chosen signal.
      • Note the output or wire label code and the module label code.
      • Use the codes to locate the module and the output or signal wire in your machine panel. The easiest place to access it may either be at an I/O bank or at the module/relay that the signal goes to.
      Identify nearby power outputs
      ‍
      It is usually best to find existing 24V and 0V or ground outputs on the same module as the selected signal(s).
      • Identify a +24V (or +12V if applicable) power output on your machine.
      • Identify a 0V ground output (usually different than the chassis or earth ground).
      • Refer to the same page on the schematic and the page for the machine DC power supply to confirm the appropriate outputs if you are not sure.
      • Place the aggregator near the relevant outputs if you haven’t already done so.

      Connect to your machine

      Connect to power
      • Cut two insulated wires and strip the ends. They should be long enough to connect the power outputs to the aggregator.
      • Use one wire to connect the +24Vdc output to the corresponding screw post input on the aggregator (first, outermost screw post with red label).
      • Use the other wire to connect the 0Vdc to the corresponding screw post input on the aggregator (second screw post with black label).
      • If successfully connected, the rightmost LED (labeled “PWR”) should light up when the machine is powered on and +24V power is available.
      Connect to the chosen signal
      The signal will be connected with a single wire.
      • If capturing an existing signal, simply slip the new wire into the output alongside the existing one.
        Tight fit? You may need to remove the existing wire, twist the new one around it, and then reinsert it.
      • If using an empty output, insert the new wire as normal. The wire can then be screwed into the digital aggregator’s input.

      Aggregator for utilization and cycle counts

      INSTALL THE AGGREGATOR

      Steps at a glance

      This part of the installation will require you to connect the aggregator and oftentimes to study your machine schematic to identify the utilization signal you'll be working with.

      DOWNLOAD DATA SHEET

      Connect the aggregator

      Mount aggregator

      Place the aggregator inside the machine’s power panel (or outside panel if using an external sensor).

      Connect aggregator to gateway or existing device
      ‍
      • If an existing aggregator is installed: Connect the new aggregator via CAT5 cable to the existing device's CAT5 second CAT5 jack.
      • If there is no existing device: Connect the aggregator to the gateway via CAT5 cable using either CAT5 jack.
      Verify connection

      Check for a solid blue LED light in the lower left corner of the digital aggregator.

      This indicates power and successful gateway connection.

        Connecting for utilization


        How are you measuring utilization?

        As a rule of thumb, start by determining how the machine performs its primary function:

        Motor (e.g. lathes, mills, saws) → analog sensor
        Other (e.g. pneumatics, hydraulics) → digital inputs

        Analog sensor (clamp)
        Digital inputs (wires)
        Clip sensor


        Clip the sensor over a wire carrying AC power to the motor performing the primary process of the machine (e.g. spindle motor power supply output).
        ‍
        If there are multiple wires for the 3 AC phases providing power to the same motor, pick any wire. The wire must contain only a single phase of power and not have a ground inside.

          Plug sensor into aggregator
          ‍

          Plug the sensor cable into the aggregator’s first available analog input port.

          If you have multiple sensors, start at port 1 and plug the rest into ports 2 and then 3.
          ‍
          The aggregator should show a blue power light (bottom left) and a blue connection light under each connected analog port (top).

            Choose a suitable signal for utilization
            ‍
            • A signal that remains in the “on” state for the entire cycle (e.g. “chuck clamp closed” signal).
            • A signal that changes states 1+ times during production (e.g. the control signal for a solenoid on a machine with pneumatic or hydraulic components that fire multiple times per cycle).
            • An external sensor (e.g. proximity switch, light curtain, or line beam sensor) if your machine does not have a suitable signal to represent ongoing production.
            See the data sheet for wiring diagrams on common ways to connect a signal.
            DOWNLOAD DATA SHEET
            Locate the signal in your machine
            ‍
            • Go to the page that lists “Machine I/O” or “Outputs” in your machine schematic or wiring diagram.
            • Find the name corresponding to your chosen signal.
            • Note the output or wire label code and the module label code.
            • Use the codes to locate the module and the output or signal wire in your machine panel. The easiest place to access it may either be at an I/O bank or at the module/relay that the signal goes to.
            Identify nearby power outputs
            ‍
            It is usually best to find existing 24V and 0V or ground outputs on the same module as the selected signal(s).
            • Identify a +24V (or +12V if applicable) power output on your machine.
            • Identify a 0V ground output (usually different than the chassis or earth ground).
            • Refer to the same page on the schematic along with the page for the machine DC power supply to confirm the appropriate outputs if you are not sure.
            • Place the digital aggregator near the relevant outputs if you haven’t already done so.
            Connect to power
            ‍
            • Cut two insulated wires and strip the ends. They should be long enough to connect the power outputs to the aggregator.
            • Use one wire to connect the +24Vdc output to the corresponding screw post input on the aggregator (first, outermost screw post with red label).
            • Use the other wire to connect the 0Vdc to the corresponding screw post input on the aggregator (second screw post with black label).
            • If successfully connected, the rightmost LED (labeled “PWR”) should light up when the machine is powered on and +24V power is available.
            Connect to the utilization signal
            ‍
            The signal will be connected with a single wire.
            • If capturing an existing signal, simply slip the new wire into the output alongside the existing one.
              Tight fit? You may need to remove the existing wire, twist the new one around it, and then reinsert it.
            • If using an empty output, insert the new wire as normal. The wire can then be screwed into the digital aggregator’s input.

            Connecting for cycle counts

            First you must identify which signal you will be working with. Then, you’ll locate that signal in your machine’s power panel and identify the nearest power outputs.

            Choose a suitable signal for for cycle counting
            ‍

            It’s critical to choose a signal that changes back and forth exactly once per cycle.

            • M-Code: Program a spare M-Code output (if available) into your end-of-program macro (e.g. an M30) to momentarily turn the output on when the count should be registered.
            • Other high-accuracy options include existing signals in your machine:
              - Part presence or proximity sensor output
              - Bar feeder control
              - Chuck clamp closed
              - Solenoid control (for pneumatic or hydraulic actions that happen once per cycle)
              - Control for any other discrete operations that happen once per cycle
            • If your machine does not have a suitable signal that can represent ongoing production, then installing an external sensor may be the best option (e.g. proximity switch, light curtain, or line beam sensor).
            See the data sheet for  wiring diagrams on common ways to connect a signal.
            DOWNLOAD DATA SHEET
            Locate the signal in your machine
            ‍
            • Go to the page that lists “Machine I/O” or “Outputs” in your machine schematic or wiring diagram.
            • Find the name corresponding to your chosen signal.
            • Note the output or wire label code and the module label code.
            • Use the codes to locate the module and the output or signal wire in your machine panel.
            Connect to the chosen signal
            ‍
            • The signal will be connected with a single wire.
            • If capturing an existing signal, simply slip the new wire into the output alongside the existing one.
              Tight fit? You may need to remove the existing wire, twist the new one around it, and then reinsert it.
            • If using an empty output, insert the new wire as normal. The wire can then be screwed into the digital aggregator’s input.

            COMPLETE CONFIGURATION

            Set up your machine in the Amper app
            Utilization must be set up first before any cycle count add-ons.
            • Go to https://app.amper.xyz (or click "complete configuration" below).
            • Go to Settings > Hardware Screen if you're not automatically directed to the instructions.
            • Click "new machine" to begin configuration. The app will guide you through entering your machine and utilization information.
            complete configuration
            Sit back

            Amper will automatically look for a production sample. If we are unable to find one, we’ll contact you to provide it manually.

            If you'd like to check in on the process, check out these two resources:
            ‍
            1. Action items. Navigate to Settings > Hardware. At the top, you'll see a summary of any machines need attention. Each action item (if any) will detail what needs to be done and who is responsible (whether your team or the Amper team).
            ‍
            2. Calibration status. Navigate to Settings > Calibration Status. This dashboard lets you check the calibration status of all your machines. Each machine will have its corresponding hardware details, calibration status, and latest update timestamp.

            Navigation

            Browse the installation guides for different aggregators, connections, and metrics.

            Back to installation hub
            sales@amper.xyz(773) 985-4582

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            Chicago, IL 60642

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