Installing Amper's aggregator with Wi-Fi

This guide is for tracking automated cycle counts. For utilization, read this guide.

Before you begin...

Set your teams up for success
  1. Have your IT team configure your Wi-Fi network. Your guide will include the technical specs they need.
  2. Schedule time to turn off machines (if required). We recommend you plan in advance so that you can safely open up the machines' power panels.
  3. Plan installation time with maintenance staff. You’ll need a team member who is familiar with the machines' operations and electrical panels.
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Installation on 2 machines should take 30–60 minutes.
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Make sure to discuss availability with any relevant staff for successful installation.

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.

CONNECT THE GATEWAY

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Make sure your network is ready for Amper devices!
If this information looks daunting, don’t worry. These are standard configurations that your IT team will be familiar with.

Make sure your network is ready for Amper devices

Verify network and gateway compatibility
  1. Supported networks:
    - Both 2.4GHz and 5GHz
    - WPA2 (most common)
    - WPA
    - WEP
    - Unsecured/open
  2. Unsupported networks:
    - WPA-2 Enterprise networks
    - WPA3
    - Hidden SSID networks
    - Networks that require a captive portal login (e.g. guest network with login or terms agreement popup)
    - Static IP assignment (Note: If you wish to assign a device to a specific IP address, you must allocate one in your network's DHCP settings based on the device's MAC addresses, which Amper can provide if needed.)
Configure your network for devices

All device connections are outbound, but devices both send and receive data on each connection. Make sure that the following domains and ports are whitelisted in your firewall.
(You must whitelist using the domain, not the resolved IP address.)

  1. Required service: Particle (device management)
    - Protocol: UDP
    - Port: 5684
    - Destination: *.udp.particle.io
    - Notes: Dynamic IP pool; firewall must use domain and not resolved IP addresses.
  2. Required service: AWS (data transfer)
    - Protocol: TCP
    - Port: 8883
    - Destination: a1z2vcintpz3vi-ats.iot.us-west-2.amazonaws.com
    - Notes: Dynamic IP pool; firewall must use domain and not resolved IP addresses.
  3. Legacy required service: Particle (legacy gateways without button only)
    - Protocol: TCP
    - Port: 5683
    - Destination: device.tcp.particle.io
    - Notes: Dynamic IP pool; firewall must use domain and not resolved IP addresses.
  4. Device MAC addresses whitelisted
    If your network restricts access to unknown devices by MAC address, go to the Hardware page in the Amper app to download your device MAC addresses for your network administrator.

Configure gateway

Once you receive your gateways and make the necessary network updates, you will have to configure them to connect to your local network. This process uses Bluetooth Low-Energy (BLE) for setup.

Plug power supply into AC outlet and gateway
  • This requires a 110V outlet.
    An outlet that is always powered on is preferred, but a built-in outlet on the machine will work.
    If no outlet is available, you'll need to run an additional outlet to the machine.
  • The gateway’s top LED light will turn blue when powered on.
Follow gateway configuration steps
  • Follow the instructions.
  • Check for the normal flow of the Wi-Fi Gateway LED lights:
    - Powers on → status LED blinks blue
    - Connects to Wi-Fi → signal LED turns green/yellow/red depending on strength
    - Connects to AWS Cloud → status LED turns steady blue
  • If the lower LED doesn't turn on after a few minutes, please double check your network selection and password and try configuring the device again.

    Need more help? Reference the device troubleshooting flowchart.
  • Open http://setup.amper.xyz on your device’s web browser.
    For iOS devices, you must download and install the Bluefy browser.
    All other devices (Android, Mac, Windows) can use the Chrome browser as long as the device supports BLE.
Mount gateway
  • The gateway should be placed as high as possible on a wall or machine exterior.
    Do not place the gateway in the machine's e-panel.
  • It should also be able to reach the machine’s power panel with the 25’ CAT5 cable as well as its power outlet.
  • Place the gateway where the LED shows up green or yellow, indicating sufficient signal strength.

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
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    • 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
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    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.

    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:
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    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).
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    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
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    Chicago, IL 60642

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