GSI Electronics EDGE 2 System User manual

REV 02
QSG 892-00096 REV02
Functional Ground Terminal. Primarily
used for functional earth terminals which
are generally associated with test and
measurement circuits. These terminals
are not for safety earthing purposes but
provide an earth reference point.
Cumberland
AP
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NOTE: This guide does not provide detailed
installation, safety or operational instructions.
See the EDGE 2 System Manuals for complete
information. Please scan the QR Code to access the
complete manuals or visit the website:
Cumberland: http://www.cumberlandpoultry.com
AP: http://www.automatedproduction.com
• Only properly trained service personnel may
perform installation and service procedures.
(In other words: electricians, service personnel
employed by or active in an organization, business,
or service).
• All power sources must be disconnected prior to
wiring and installing.
• Disconnects are required to de-energize power to
the EDGE 2 system.
• Make sure to separate high voltage wiring from low
voltage (Class 2) control wiring.
• Use copper wires only.
• A minimum temperature insulation cable rating of
90°C (194°F) is required from the Expansion Box.
• EDGE network cables (Automation and Safety)
have to use Class 1 load type. TC-ER cable type is
recommended.
• Refer to the Wiring Methods and Materials section
from the National Electric Code to use the correct
wire for the installation.
• Electrostatic discharge (ESD) can damage
equipment and impair electrical circuitry. ESD
damage occurs when electronic components are
improperly handled and can result in complete or
intermittent failures.
• Warranty is void if the EDGE 2 System is used in a
manner not specied by the manufacturer.
GSI Electronics Inc.
5200 Armand Frappier Saint-Hubert, Qc
Canada J3Z 1G5
Phone: [phone]
E-mail: [email protected]
EDGE 2 System
Quick Start Guide
1 - NOTICES
WARNING: Read the following text
carefully; it contains important information
which, if ignored, may cause the controller
to operate improperly.
High Voltage. Hazard of electrical shock.
Protective Earth Ground Terminal. Primarily
used for protective earth terminals. These
terminals connect to conductive parts of
a device for the purpose of safety and is
intended to be connected to an external
system for protective grounding.
3 - SYMBOLS
4 - PRE-INSTALLATION GUIDELINE
EN
The EDGE 2 is manufactured by GSI Electronics Inc.,
Canada.
2 - REFERENCE DOCUMENTS
Details on installation and initial conguration of the
EDGE 2 System can be found in the EDGE 2 System
Installation Manual #890-00687.
Details on the operation of the EDGE 2 System can be
found in the EDGE 2 System User’s Manual #890-00686.
Details on wiring diagrams of the EDGE 2 System can
be found in the EDGE 2 System wirings diagrams:
#891-00596: EDGE 2 - Non redundancy System
#891-00597: EDGE 2 - Redundancy System
#891-00598: EDGE 2 - General information
4-1-1. WAN/LAN Network
4-1. Installation Options
The LAN network can be setup to reach outside
Ethernet cables or wirelessly using a Cellular based
network to reach an Ethernet service provider (WAN).
Depending on the option you choose, the planning
and installation will be dierent.
• For an Ethernet setup, make sure there is access to
high speed Internet.
• For a Cellular based network, plug the cellular
base to the external USB connector on the EDGE 2
enclosure with a sealing rating of IP54 or Nema 12.
• No Redundancy Main Controller: Ethernet is used
only for remote connection purpose.
4-1-2. Redundant Controller and LAN\WLAN Network
You can setup a redundant Main Controller, in case the
Main Controller Master fails. Use of a redundant Main
Controller will determine its communication scheme.
• Redundant Main Controller using internally wired
Ethernet (LAN) network
• Redundant Main Controller using internally wireless
Ethernet (WLAN)
• Redundant Main Controller using Cellular network
• No Redundancy Main Controller: Ethernet is used
only for remote connection purpose.
4-1-3. Redundant Power Supply
The EDGE 2 System can be setup to use a redundant
power supply or not. Depending on the option you
choose, the planning and installation will be dierent.
For a system without a redundant power supply:
• Use the Automation link and do not wire the 24Vdc
wire between Expansion Boxes. (84W max of DC
load on 3 Slot Expansion Box and 48W max of DC
load on 6 Slot Expansion Box).
For a system with a redundant power supply:
• The controller groups must be divided into
subgroups of two Expansion Boxes (28W max of DC
load with 6 Slot Expansion Box, 60W max of DC load
with 3 Slot Expansion Box).
INSTRUCTIONS: Divide the total group of Expansion
Boxes by 2 to make a subgroup of two Expansion
Boxes. If there is an odd group of Expansion Boxes,
you can make an even group using one of the
following options:
» A) For a 6 Slot Expansion Box => use two 3 Slot
Expansion Boxes.
» B) Use an Expansion Box with an external power
supply of 150 Watts wired on the Safety Network.
• Use dual links on (Automation | Safety).
NOTE: To form a subgroup of three, call AP / Cumber-
land.
4-1-5. Failsafe Plug-in Modules
You can purchase Failsafe Plug-In Modules that relay
output contacts if the relay coil is de-energized in the
event of a power outage.
NOTE: Failsafe Plug-In Modules enter into a Failsafe
Mode when powered down.
4-1-6. Backup Mode
If the Main Controller Master and EDGE Main Controller
Redundant are not able to communicate with the
modules, backup mode will allow the modules
to autonomously control the environment with
minimum system controls. To optimize the use of
Backup Mode, link an input feedback and an output to
the same module.
4-2. Power Supply
The power consumption of EDGE 2 Controllers are
similar to the previous EDGE Main Controller. To
upgrade an EDGE system, swapping out the Main
Controllers is very easy if no new hardware features
are implemented.
For example, new cellular bases are installed to a
current system. This new feature could overload the
power consumption of Expansion Boxes. To solve
this problem, use an EDGE PSU 24V 36W close to the
problematic EDGE 2 Controller and supply it directly.
This solution can also be used in the case of voltage
drop on an EDGE network that may be too long.
The maximum distance of the DC power
cable is 450ft (137.6m) with a wire gauge of
16AWG in redundant power supply from the
rst EDGE Expansion Box in a group of two
to the last EDGE 2 Controller on the EDGE network
(see redundant schemes). Over this distance, use an
EDGE PSU 24V 36W to supply power to the EDGE 2
Controllers. In this case, do not use the 24Vdc from the
EDGE Expansion Box. In no redundant power supply
scheme, the maximum distance of the DC power cable
is 500ft (150m) with a wire gauge of 16AWG.
4-3. EDGE 2 Controller Screenless
The EDGE 2 Controller Screenless can be used only as
a Redundant Main Controller in a redundancy system
scheme.
NOTE: Use only Ethernet cables with EDGE 2 Controller
Screenless for Ethernet network. The router must have
DHCP function when using this type of controller.
TP-767
4-1-4. Redundant Communication between Devices
The system uses redundant communication between
the Expansion Boxes, external modules, and the main
and redundant controls.
• For an redundant communication setup, use dual
links for (Automation | Safety).
• For a system without redundant communication,
use the Automation links.

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4-8. WiFi Network
The WiFi signal has maximum coverage when the
access point is in a non-obstructed line of sight.
Wooden walls and ceilings lower the WiFi signal
strength. Metal support beams or girders will create
low signal WiFi areas and metal or aluminum covered
walls will block the WiFi signal.
The access points have a typical coverage of
10,000sqft. When not obstructed, this is a square of
100’ by 100’. The signal is still there at 110’, but it’s no
longer optimal and its strength cannot be predicted.
If shaded by a beam, this distance can be considerably
less. The access point emits a signal horizontally in a
circular manner. It should be mounted in the center
of the desired coverage area. Remembering that the
coverage area is a circle around the access point, wall
mounting is not recommended. When mounting the
access point on a wall, it should be oriented properly
and mounted as high as possible.
Planning the location and quantity of access points
should be done with the plans of the barn. Place an
access point on the ceiling for each 100’ x 100’ square
and locate the EDGE 2 Controllers with direct view of
the access points.
5 - INSTALLATION
The following items must be in place before the EDGE 2 System can be installed:
• Ethernet WAN infrastructure and network operator services
• Ethernet LAN infrastructure
• Electrical wiring and outlets for communication network
• Ethernet communication cables if it is required
EDGE 2 System Installation Order
1 - Physical Installation
Install the EDGE system on the wall according to the plan by respecting the cable distances between controllers,
their minimum clearances, and other restrictions:
• EDGE Expansion Boxes and equipment
• EDGE External Modules (EDGE Bird Scales, EDGE Bin Scales, EDGE RS485 Repeater, EDGE Power Modules, EDGE
Weather Station) and equipment
• EDGE 2 Main Controller
• EDGE 2 Redundancy Controller
• EDGE 2 Remote Display
• Installation of Ethernet cabling
2 - Module Detection
After turning ON the EDGE 2 system, the EDGE will detect the modules on EDGE Network.
NOTE: The EDGE has to upgrade the modules rmware during module detection. This operation can take a few
minutes. DO NOT CONFIGURE CONTROLLERS UNTIL THE FIRMWARE UPDATES ARE COMPLETE.
3 - Ethernet EDGE 2 Controller Conguration
Set your Ethernet link if redundancy scheme is used and/or remote control is required: by Ethernet cables (LAN)
or by Ethernet WiFi (WLAN).
4 - Software Update (optional)
You can check to make sure if a software update is available, by going to Menu->Software Update.
4-6. EDGE Network Design
Automation and Safety bus have to be wired in
daisy chain. Use EDGE RS485 Repeater to extend the
network length or to create sub networks.
An EDGE RS485 allows the network to be extended by
1500ft (457m) when using only a communication link
without supplying DC power on an EDGE module at
the end.
NOTE: Up to 5 EDGE RS485 Repeaters can be used in
series to extend the network branches.
4-7. Ethernet Network
GSI Electronics recommends the use of another
Ethernet protection step when the Ethernet cable
has to go from one barn to another using the
Ethernet switches. This recommendation is applicable
regardless of the way it is used to link both barns.
For a majority of installations inside a barn, a minimum
unshielded twisted pair (UTP) Cat5 Ethernet cable or
higher category can be used.
In environments with a lot of electrical noise, (for
example, close to a high voltage cable, a frequency
drive, or a light control device), a shielded twisted pair
cable is recommended. A shielded twisted pair with
braid is recommended for a link between two barns.
External Module Type
EDGE 1 System EDGE 2 System
External Module Name Power consumption on
DC network External Module Name Power consumption on DC network
Master Main Controller EDGE Main Controller 19W Replaced by EDGE 2 Main Controller 24W
Remote Display EDGE Remote Controller Connected on AC network directly.
No impact on EDGE DC network.
Replaced by EDGE 2 Remote Display.
Recommend using it with EDGE PSU 24V 36W. 24W
Redundant Main Controller EDGE Main Controller 19W Replaced by EDGE 2 Main Controller 24W
Redundant Screenless
Main Controller Does not exist Does not exist Use EDGE 2 Controller Screenless 17W
4-10. EDGE System Comparison
4-11. Variable Light Dimmer Outputs
By using EDGE 4IN-6R-2LD modules, EDGE 2 system allows 8 Amps lights dimming per channel in a livestock
building. It has been designed to accommodate various models of dimmable compact uorescent lights (CFL),
dimmable cold cathode uorescent lamps (CCFL), dimmable Light Emitting Diodes (LED).
GSIE Part Number Name Description
064-00498 EDGE 4IN-6R-2LD This module has 4 analog inputs, 6 relay outputs normally opened, and 2 independent light dimmer outputs
064-00499 EDGE 4IN-6R-2LD This module has 4 analog inputs, 6 relays with two dierent outputs: normally opened and normally closed, and 2
independent light dimmer outputs
NOTE: CFL and CCFL lamps must be ELV ballast type (electronic only).
Only two EDGE 4IN-6R-2LD or two EDGE 4IN-6R-2LD Failsafe Modules are allowed per Expansion Box. Both
modules can be used in either the 6 Slot Expansion Box or the 3 Slot Expansion Box. In a 6 Slot Expansion Box,
EDGE 4IN-6R-2LD cards have to be installed into slot 1 and slot 6. In a 3 Slot Expansion Box, EDGE 4IN-6R-2LD
cards have to be installed into slot 1 and slot 3.
4-12. Supplying Power to EDGE Scales
Use an external power supply for EDGE Scales.
4-5. Equipment and Load Planning
According to the needs, the installer manual gives
the maximum output rating accorded per load or
equipment type. According to the maximum output
rating, the number of equipment or loads allowed per
output is limited per the power factor or the service
factor of the equipment or loads.
4-9. Power Rating of the External Modules
To calculate the total power consumption on the Expansion Box via EDGE network from the modules, add
together the power consumption of each module.
External Module Name Power Consumption
EDGE Bird Scale 5W
EDGE Bin Scale 5W
EDGE Weather Station 4W
EDGE RS-485 Repeater 2W
EDGE 4IN-2V-8DO 8W
EDGE 2 Remote Display 24W
EDGE 2 Main Controller 24W
EDGE 2 Controller Screenless 17W
4-4. EDGE 2 Remote Display
Use the EDGE PSU 24V 36W to power the EDGE
2 Remote Display. This will make sure the EDGE
Expansion Box power supply is not overcharged.
The EDGE 2 Remote Display needs an EDGE 2 Main
Controller to control the EDGE system indirectly.
An EDGE network without a Main Controller is
impossible.
For a barn that is 230’by 100’ and has few wooden or metal obstacles, use two access points. If the WiFi signal
must go through wooden walls, it is better to use 3 access points. As metal walls essentially block the WiFi signal,
there must be one access point per metal room. These are guidelines and experimentation may be required to
create a WiFi network that delivers a strong signal to each component.

Making a Group of Expansion Boxes for a Redundant Power Network:
Divide the total group of Expansion Boxes by two to make a subgroup of two Expansion Boxes.
If there is an odd group of Expansion Boxes, you can make
an even group using one of the following options:
» A) For a 6 Slot Expansion Box => use two 3 Slot
Expansion Boxes.
» B) Use an Expansion Box with an external power
supply of 150 Watts wired on the Safety Network.
Requirements for external power supply
Minimum power: 150W
Nominal Voltage Input: 120-240Vac
Frequency: 50/60Hz
Output voltage: 24Vdc
Output current: 6.25A
Output Ripple and Noise (20MHz BW): 100mV
Protection: Overcurrent and overvoltage (surge: 2KV)
Certication: UL or CSA
Sealing: have a power supply with a sealing (for example: IP54, nema:12)
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Backup Mode
Modules enter into Backup Mode when no
communication is received from either the master
controller or the redundant controller for 2 minutes.
Modules do not communicate with each other in
Backup Mode.
Backup Mode is a degraded thermostatic control
derived from the controller’s conguration.
Temperature controlled equipment uses an average
of the assigned temperature probes on the module.
Temperature driven equipment default to Failsafe
when its module does not have a temperature probe.
Equipment in bypass are kept in their bypass state in
Backup Mode.
Failsafe Mode
Modules enter into Failsafe Mode when powered
down.
6 - SYSTEM OPERATION
Conguration
The easiest way is to export an existing conguration
from an EDGE 2 or EDGE 1 system and import it to the
new EDGE 2 system.
NOTE: Light programs and multiple day schedules will
not be exported in the conguration le.
Other ways to create the conguration are by using the
WEB browser or by user interface on site.
Minimum congurations needed to operate the EDGE
system:
• Site Conguration
• Time and units
• User Management
• Rooms
• Site Name
• Controller Name
• Equipment conguration
• Room Setup
Normal Mode
EDGE system automatically controls the equipment
according to their settings and the input feedback
or according to a scenario in the automatic mode.
The EDGE system can also control the equipment in
manual mode.

Redundant Pattern Scheme Max Distance
• 18 AWG = 100 ft Max distance
• 16 AWG = 140 ft Max distance
• 14 AWG = 230 ft Max distance
Goal: to get max distance on EDGE Main Controller
side (Distance 1) and shorter distance between EDGE
Expansion Boxes (Distance 2)
Wire gauge Max distance 1 Max distance 2
18AWG 200 ft 50 ft
16AWG 400 ft 50 ft
14AWG 400 ft 150 ft
Goal: to get max distances between EDGE Expansion
Boxes (Distance 2) and shorter distances on EDGE
Main Controller side (Distance 1)
Wire gauge Max distance 1 Max distance 2
18AWG 10 ft 60 ft
16AWG 10 ft 100 ft
14AWG 10 ft 170 ft
• 18 AWG = Max distance 1: 50 ft
• 16 AWG = Max distance 1: 100 ft
• 14 AWG = Max distance 1: 150 ft
Communication only
(with gnd)
The max distance of communication link allowed in between each end side of a specic network could be up to 1500 ft.
An EDGE RS485 allows the network to be extended by 1500ft (457m) when using only a communication link without supplying
DC power on an EDGE module at the end.
NOTE: Up to 5 EDGE RS485 Repeaters can be used in series to extend the network branches.
Redundant Pattern Scheme and Distances According to the Wire Gauge
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To supply EDGE 2 Controller without Expansion Boxes Max Distance
• 18 AWG = 370 ft Max distance
• 16 AWG = 500 ft Max distance
To Power Expansion Boxes with Greater Distances Max Distance
• If the distances with power required in between
EDGE Expansion Boxes in a subgroup or not are
greater than the max distances, convert the group
to a group with only communication in between
and using external power supplies.
Supplying Power
Non-Redundant Pattern Scheme and Distances According to the Wire Gauge
Non-Redundant Pattern Scheme Max Distance
• 18 AWG = 370 ft Max distance
• 16 AWG = 500 ft Max distance
Wire gauge Max distance 1 Max total distance
18AWG 370 ft 1500 ft
16AWG 500 ft 1500 ft
Communication only
(with gnd)
The max distance of communication link allowed in between each end side of a specic network could be up to 1500 ft.
An EDGE RS485 allows the network to be extended by 1500ft (457m) when using only a communication link without supplying
DC power on an EDGE module at the end.
NOTE: Up to 5 EDGE RS485 Repeaters can be used in series to extend the network branches.
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