Connecting Signals to the Digital Aggregator for Automated Counts

Connecting Signals to the Digital Aggregator for Automated Counts

This article is about using the Digital Aggregator to collect automated cycle counts. To use a Digital Aggregator for utilization data collection, see the article below:

Connecting to Machine DC Power

For the digital inputs to function properly, the device must be connected to 24VDC power. This allows the device to properly interpret the signals it measures. The power input must be connected to +24V or +12V and to ground (or 0V/common). The device consumes under 10mA via this power input and should not significantly load the system.

  1. Identify an available +24V (or +12V if applicable) power output on your machine. This is best with an unused output, however, it is usually okay to use an output that is already in use, as the device requires very low power.
  2. Identify a 0V ground output. This is usually different than the chassis or earth ground, and is often identified as 0V instead of ground.
  3. Cut two insulated wires to length and strip the ends. These should be long enough to connect the power connections to the Digital Aggregator.
  4. Use one of these wires to connect the +24V output you identified to the correct screwpost input on the Digital Aggregator. In the picture below, the +24V would attach on the left side. Use the other wire to connect the 0V ground. The 0V ground wire would attach to the right side, leaving the middle intentionally empty.

If successfully connected, the rightmost LED should be on when the machine is powered on and +24V power is available.


Connecting The Digital Input(s)

Now it is time to connect the signal(s) you identified. If you are not sure:

  1. Locate the signal in the machine's panel. It is easiest to use the machine's schematic to determine the code that identifies the wire in the panel. Once identified, find a place where that wire is screwed into place. This could be an input, output, or interconnect.
  2. Cut and strip an insulated wire long enough to reach the Digital Aggregator from the identified location.
  3. Before proceeding, you may want to turn off or pause the machine to prevent any temporary issues during installation.
  4. Carefully unscrew the existing connection far enough to be able to insert the wire you just cut. The new wire should lay on top of the existing one. Then, carefully screw the connection point firmly back into place, ensuring that it makes snug contact with the wires.
  5. Finally, connect the other end of the wire you cut to one of the inputs on the Digital Aggregator. You can connect to either of the two screwpost inputs for that input number—they are internally connected to allow for pass-through or termination if required. Do NOT connect the other input terminal directly to ground or power.
  6. If using a sensor that isn't connected to a PLC or other load, you must connect an additional load to ensure signal changes are captured properly. When using a PNP type sensor (active high), the load should be connected between the second screwpost on the input and the 0V screwpost. When using an NPN type sensor (active low), the load should be connected between the second screwpost on the input and the +24V/+12V screwpost. Usually, a passive resistor of 5.1k ohm will work for the load, but consult the manual for your sensor to make sure it is within range.

If successfully connected, once the machine is on and running, you should see the LED corresponding to the digital input turn on when the signal voltage is high, and turn off when the signal is low.


Next Steps

Once you have finished installing the Digital Aggregators, you will need to submit a form to your Amper Customer Success Representative.