Cooper controls Greengate ck4-120no Assembly instructions

ControlKeeper®4

INSTALLATION SHEET

Model# CK4-120NO-

Model# CK4-277NO

General Information

The ControlKeeper-4 model is shipped in one package and

is congured with either a 120V or a 277V transformer. It is

factory congured with Normally Open relays. Please refer

to your order information to determine which model you have

purchased.

Getting Started

1. Do not discard these installation instructions. Please keep

for future reference and operation information.

2. Always disconnect all power before wiring.

3. Use only as intended and at the listed voltage.

4. All installation and service must be performed by qualied

personnel or service technicians.

5. Install in accordance with the National Electrical Code and

any other codes which may apply.

6. Installation and wiring information contained in this docu-

ment is based on industry-accepted standards and prac-

tices. If conicts exist between these instructions and any

applicable codes or ordinances, please contact Greengate

before proceeding with the installation.

7. High Voltage is present inside the enclosure. Use extreme

caution when performing maintenance on this equipment.

Failure to follow this warning and proper safety procedures

could result in severe injury or death, and/or damage to

the equipment.

8. Document all wiring and device terminations and loca-

tions so that devices can be properly congured and

programmed for operation.

Mounting the Cabinet

1. Choose a dry location on a rm surface convenient to the

circuits being controlled. Allow full clearance for the door

of the enclosure to open fully.

2. Mount the ControlKeeper-4 cabinet using the holes pro-

vided in the back of the enclosure. It is recommended that

the panel be mounted vertically.

3. All Line Voltage conductors must enter the cabinet on the

right side of the enclosure.

4. All Low Voltage conductors must enter the cabinet on the

left side of the enclosure.

5. Remove all debris and metal shavings from the enclosure

before applying power to the ControlKeeper-4.

Figure-1 ControlKeeper-4 Enclosure

Power Supply Wiring

The ControlKeeper-4 is factory congured with either a 120V

or a 277V transformer. Transformer voltages are color coded.

It is recommended that a dedicated branch circuit with circuit

protection be used for power supply wiring.

1. Connect neutral wire to the white wire.

2. If the transformer is a 277V model, connect orange wire to

a 277V circuit. If the transformer is a 120V model, connect

black wire to a 120V circuit.

Figure-1 ControlKeeper-4 Enclosure

Connecting Relay Loads

1. Test branch circuits for short circuits prior to connecting and

energizing the ControlKeeper-4.

2. Relay terminal blocks have a maximum limit of 10 AWG wire.

3. Relays are rated for single-pole circuit use. Connection of 2

pole circuits/loads to the ControlKeeper-4 will void the

equipment warranty.

4. Connect a 120 or 277 volt, 20 amp maximum, de-en-

ergized branch circuit breaker to the relay terminal block

position labeled LINE.

Line = 120V (Black),

277V (Orange)

Neutral = White

277V Transformer

Line = Orange

Neutral = White

120V Transformer

Line = Black

Neutral = White

Cooper Controls

203 Cooper Circle, Peachtree, GA 30269

800-553-3879

www.coopercontrol.com

5. Connect the load to the output terminal block position la-

beled LOAD.

6. Tighten down relay terminal screws. Manufacturer’s recom-

mended torque rating is 7lbs-in. (0.59 lbs-foot) (0.8Nm).

Figure-6 Address Switch Information

Note: Neutrals terminate within the adjoining lighting panel.

Network Wiring Notes

The ControlKeeper-4 is designed to communicate with other

ControlKeeper network panels using a lighting control RS-485

network for communications. This allows the panels to share

information and to be programmed from one central location

by a computer with the Keeper Enterprise Software.

Please refer to Table-1 for information on recommended wiring

for network.

Acceptable

Network Wiring

Suggested Cable

Standard RS485 Belden 9841 (shield is not used)

Plenum RS485 Belden 89841 (shield is not used)

Table-1 Network Wiring Recommendations

For best network performance, one of the suggested cables

should be used. If the specied cable is not used and

communications problems occur that require troubleshooting

assistance, additional charges for support may be assessed.

1. All low voltage wiring is Class 2.

2. All low voltage wiring must enter the cabinet from the left

side of the enclosure.

3. All low voltage wiring must be run in separate conduit from

line-voltage wiring.

4. Test all network wiring for shorts to AC ground before con-

necting to the ControlKeeper-4 panel.

5. If using Belden 9841 or 89841, leave all shields disconnected

making certain that shield is not exposed.

6. Panels and devices on the RS-485 lighting network should

be daisy chained. Do not create a Star or T-Tapped

conguration.

7. Total network length should not exceed 4000 feet.

Network Wiring Details

1. Before wiring, select the two panels that are going to be

the end panels of the network and plan a wiring scheme

accordingly. Panels should be daisy chained, not Star or

T-Tapped.

2. Starting at one of the end panels, connect the network +

and - terminals to the next panel’s network + and - terminals.

Continue this process through the network making certain

to observe polarity. When nished, the two end panels will

have a single pair of wires coming into the network terminal

block while all middle panels in the network will have two

sets of wires.

3. Set the network termination jumpers. On the end panels on

the network set to the terminated position. For all panels in

the middle of the network, remove the network termination

jumper. See Figures-4&5 for details.

4. On the two end panels in the network, set the network

termination jumpers to the terminated position.

5. On the middle panels in the network, remove the network

termination jumpers.

6. Set all panel addresses using the panel network identica-

tion DIP Switches on each panel. See Figures 5&6 for

location and details.

7. Using the panel reset switch, issue a soft reset to each panel

to initialize the panel address. See Figure-5 for location of

the reset switch.

Page 2

Figure-4 Network Wiring Detail

Figure-5 Item Reference for Network Details

All panels must be assigned a unique Network Address in order to

communicate over the lighting network. Switch positions are

labeled 1 through 8 and are valued at 1 through 128 as shown above.

The network address is calculated by adding the value of the switch

positions that are in the ON position. In the example above,

switches 1 and 3 are ON giving the panel the network address of 5.

Addresses 1 through 254 are valid addresses. Zero and 255 are

reserved for system use. To initialize the network address with the

controller, press the panel reset button after the address is set.

Figure-6 Address Switch Information

Connecting Low Voltage Inputs

The ControlKeeper-4 logic board can support both dry contact

closure and Digital Switch inputs. If a combination of contact

input switches and Digital Switches are being used, the com-

bined total cannot exceed 64 inputs.

Regardless of input type used, it is recommended that all input

wiring be done prior to applying power to the logic board or at

the very least with the terminal blocks removed from the logic

board. Please verify that there are no shorts to AC Ground

prior to connection of input devices. Regardless of input type,

the following notes apply.

1. All low voltage wiring is Class 2 wiring.

2. All low voltage wiring must enter the cabinet into the Low

Voltage section of the enclosure. Low Voltage wiring can be

brought into the enclosure from the left side of the enclosure.

Failure to separate high voltage from low voltage wiring

may cause interference with logic board function.

3. All low voltage wiring must be run in separate conduit from

line voltage wiring.

4. Test all low voltage wiring for shorts to AC ground before

connection to the relay panel.

5. When powering peripheral devices such as motion sensors

and photosensors from the ControlKeeper-4 panel, there

may be a limitation on the number of sensors that can be

supported. This is also true if Digital Switches are used with

the system. See the recommendations below or contact

Cooper Controls for further information.

6. It is recommended that the terminal blocks be removed from

the board or power removed from the logic board when

doing initial switch input wiring.

Contact Input Switch Wiring

This section describes the wiring for dry contact closure de-

vices. There are four switch input wiring terminals on the left

side of the ControlKeeper-4 to allow for wiring of the dry contact

closure devices.

1. Use 18 AWG twisted, unshielded wire for all low voltage dry

contact closure device wiring.

2. Maximum length for dry contact closure device wiring is

1000 feet.

3. Please see wiring detail below for details on connections

of different devices to the ControlKeeper-4 system.

MOV1

MOV3 MOV2MOV4

TB1TB2TB3

TB4

Relay Rating: 20amps, 208/240/480V

Wire: 6 AWG Max.

Relay Wiring

Q2 Q1

LED9

LED1

LED5

U2 U1

SW1

SW3

PCI 2004

CX4 TPRC

STATUS

50-022140-00

LINE

LOAD LINELOAD

To Lighting Load

To Circuit Breaker #1

To Circuit Breaker #2

To Lighting Load

Page 3

Figure-3 Standard Relay Card Wiring

Contact Input Photosensor and Greengate Sensor Note

It is possible to use a contact input photosensor and Greengate

Motion Sensors in conjunction with the lighting control system. The

ControlKeeper-4 is capable of powering a number of these devices.

Please refer to the chart below for details on how many devices the

transformer can support

Please contact technical support if it is necessary to power

additional sensors beyond the numbers listed above. These

gures do not account for additional devices such as Digital

Switches being used. If using a combination of devices, please

contact technical support for exact details on how many devices

the logic panel can power.

Photosensor and Motion Sensor Wiring

Digital Switch Wiring

Each ControlKeeper-4® panel is capable of supporting up to 7

Digital Switch device stations and 1 GDS-I gateway device (the

number the controller is able to support is dependent on the

number of other low voltage devices wired that require power

from our logic board. Please contact Technical Support for

exact details of how many devices your logic board can

power.)

Digital Switch cable type should be Cooper LC Cable,

Belden 1502R (non-plenum), or Belden 1502P (plenum).

For best network performance, one of the suggested cables

should be used. If the specied cable is not used and com-

munications problems occur that require troubleshooting

assistance, additional charges for support may be assessed.

Digital Switches do not wire directly to the ControlKeeper-4®

panel, but are wired to a CAN Bus network that connects to the

ControlKeeper-4® through a GDS-I device. Digital Switch

devices should be networked together in a daisy chain con-

guration. No T-Taps/Stars should be used. The GDS-I device

should reside somewhere within the daisy chain switch net

work. Total daisy chain network length should not exceed

1000 feet.

The following instructions describe the GDS-I device connec-

tion to the ControlKeeper-4®. Please refer to the Digital Switch

Installation Instructions for information on wiring the Digital

Switch network to the GDS-I.

1. Mount the GDS-I next to the ControlKeeper-4® panel. A

six foot phone style cable has been provided for connec-

tion to the ControlKeeper-4® panel.

2. Run a length of the Digital Switch LC or Belden cabling

from the GDS-I location to the low voltage section of the

ControlKeeper-4®.

3. Connect the RED wire in the cable to the +V terminal on

the back of the GDS-I and to the ControlKeeper-4® at

one of the switch input +24VDC terminals.

4. Connect the BLACK wire in the cable to the GND termi-

nal on the back of the GDS-I and to the ControlKeeper-4®

remote power connector GND terminal.

5. Tape back or cap the blue and white wires and shield

wire for the cable. They will not be used for connection

between the GDS-I and lighting controller.

6. Locate the 6 foot phone style cable included in the GDS-I

box. Run this from the GDS-I into the low voltage section

of the ControlKeeper-4® enclosure plugging the end with

9 pin head into the GDS-I. Plug the end the RJ11 phone

style plug into the ControlKeeper-4®.

40 16 20 20

Greengate

PIR Sensor

Greengate

Dual-Technology

Sensor

Greengate

Ultrasonic

Sensor

PPS-4

Indoor

Photosensor

PPS-5

Outdoor

Photosensor

NETWORKDIGITARS232

VDC

GND

+24

CH4

OFF

ON +24

CH3

OFF

ON +24

CH2

OFF

ON +24

CH1

OFFON +24

RESET

NET TERM

U28

U25

U26

U22

U24 U19

U20

U29

TB7

41235687

J2J1

U18

U27

U23

U21

TB5

TB4 S7

RN1

C26

C20

U17

+24VDC

OFF

Momentary Switch

(3 wire)

Toggle Switch

(2 wire)

Maintained Switch

(2 wire)

+24VDC

Page 4

Figure-8 GDS-I Wiring Detail

Applying Power

1. After wiring is complete, make certain to clean panel of all

wire clippings and fragments ensuring that no fragments

get lodged between the circuit board and enclosure.

2. Ensure that there are no loose wires or exposed wires that

could short out.

3. Make certain that the line-voltage section of the enclosure

is closed and secure.

4. Power up the unit. It is recommended that the unit be

cleared of all programming unless the unit has been sent

pre-programmed to you by the factory. To perform this step,

hold down the reset button for about 15 seconds.

5. Please refer to the operation section of this instruction for

information on turning on and off lighting loads. Refer to

the Keeper Enterprise Software manual for information

regarding the programming of the ControlKeeper-4.jumper.

Relay Override Operation

The ControlKeeper-4 has two means of override located on the

logic board: individual relay override buttons and a hardware

override switch. It is possible to control lighting loads and

override programming using these override mechanisms.

Figure-10 ControlKeeper-4 Status LEDs

Individual Relay Override Notes

Each relay on the ControlKeeper-4 may be overridden using

the individual relay override switches located at the top left

of the low voltage section. See Figure 9 for location of these

switches. These override switches will toggle the associated

relay’s state with each push of the button. This type of over

ride is temporary in that the override will last until the next

command that the relay is given.

Hardware Override Switch Notes

In addition to the individual relay override switches, there is a

hardware override switch that allows the override of all relays

on the board. If this switch is moved to the ALL ON or ALL OFF

position, all four relays will remain ON or OFF as long as the

switch is in that ALL ON or ALL OFF position. The ON or OFF

state is maintained regardless of programmed state. In order

for relays to run programmed scheduling the hardware override

switch must be in the AUTO or center position. See Figure 9

for location of the hardware override switch.

LED Operation

The ControlKeeper-4 has LEDs for status monitoring. They

consist of System Status LEDs and Relay Status LEDs.

Figure-10 ControlKeeper-4 Status LEDs

System Status LEDs

There are six (6) system status LEDs that are located in the

upper left corner of the ControlKeeper-4. Please refer to Fig-

ure 10 for location of these status LEDs. These status LEDs

will indicate proper operation or potential problems with the

ControlKeeper-4. Normal Operation includes the following

LED states.

Status LED: The Status LED will ash ON and OFF con-

tinuously under normal operation. The LED is an indication of

microprocessor health. If the LED is ON or OFF all the time,

please use the soft reset button on the controller. If the LED

does not resume normal ashing state, contact Technical

Support.

Digital Switch LEDs: These LEDs, labeled CAN-TX and

CAN-RX, will ash when Digital Switch information is being

passed back and forth between the Digit Switch Gateway and

the ControlKeeper-4.

Power LEDs: These LEDs, labeled POWER and ISO POWER,

indicate that the ControlKeeper-4 is getting the proper expected

voltage from the transformer. If one or both of these LEDs is not

lit, there is a problem with power to the board. Please contact

Technical Support for further details.

Network LED: The Network LED should ash only when ac-

tivity is present on the network wire. If communications com-

mands are not being transmitted over the network wire from

the Keeper Enterprise Software or broadcast switches and this

LED is ickering, ON constant, or ashing, it is an indication

of noise on the network wire that may interfere with proper

system operation. Please check all network wiring carefully for

shorts to AC Ground if this condition exists. Contact Technical

Support for further troubleshooting help.

NETWORKRS232

VDC

GND

+24

CH4

OFF

ON +24

CH3

OFF

ON +24

CH2

OFF

ON +24

CH1

OFFON +24

RESET

NET TERM

U28

U25

U26

U22

U24 U19

U20

U29

TB7

41235687

J2J1

U18

U27

U23

U21

TB5

TB4

RN1

C26

C20

U17

GDS-I

Page 5

Relay Status LEDs

There are four relay status LEDs, one for each of the relays

on the ControlKeeper-4. Please refer to Figure 10 for location

of these LEDs. The relay status LEDs are an indication of

whether the associated relay is energized or de-energized. If

the relay LED is ON, the relay load should be ON. If the relay

LED is OFF, the relay load should be OFF.

ControlKeeper-4 RS232 Port

The ControlKeeper-4 has an on board RS232 port for com-

munications to peripheral accessory devices or to the Keeper

Enterprise Software. This RJ style jack should not be connected

to any device not intended for use with the lighting control

system. Connection to a phone line will cause damage to the

lighting control system that is not covered under warranty.

Please use only Greengate approved device connections for

connection to this port.

System Reset and Clear Commands

Under certain circumstances, you may want to reset the Con-

trolKeeper-4. There are two different types of reset commands

available in the ControlKeeper-4 system: a soft reset command

and a clear reset command.

Soft Reset Command: A soft reset command is used to initial-

ize a new panel address with the panel. It can also be used

as a troubleshooting technique if the panel is not responding

or to free up the microprocessor if the unit’s STATUS LED is

not ashing. The Soft Reset Command will not cause loss of

panel programming. To perform a Soft Reset Command, press

in and then immediately release the reset button in the lower

right corner of the logic panel. When the reset button is pressed

and released, the status LED may hesitate briey then resume

normal operation.

Clear Settings Command: A clear settings command is used

to remove all programming from a ControlKeeper-4 unit. It

should be done before downloading programming to the unit

for the rst time or when asked to by a Technical Support

representative. Please use caution with this command! When

performing a Clear command, all relay loads will turn off. Use

the Hardware Override Switch to keep lighting on if necessary.

In order to reprogram the unit, you will need to use the Keeper

Enterprise Software. To perform a Clear Command, press and

hold down the reset button in the lower right corner of the low-

voltage section for a period of 15 seconds until the STATUS

LED turns off. Once the STATUS LED turns off, release the

reset button. The ControlKeeper-4 unit will be reset back to

factory default settings.

Programming the ControlKeeper-4

The ControlKeeper-4 is programmed using Keeper Enterprise

Software. Please refer to the Keeper Enterprise Manual for

programming details. It is recommended that a Clear Command

be performed on the controller before the rst programming

download to clear any test data that may be left in the controller

from factory testing.

Repair Information

If a repair becomes necessary on your ControlKeeper-4 unit,

please refer all service to Greengate’s technical support line

at 1-800-553-3879. The ControlKeeper-4 contains no user

serviceable parts.

Page 6

Figure-11 Item Reference

1. Individual Relay Override Switches (temporary override)

2. System Status LEDs

3. Relay Status LEDs

4. Panel Hardware Override Switch (ALL OFF, AUTO, ALL ON)

5. Transformer Wiring Leads: White = Neutral, Orange = 277V, Black = 120V

6. Relay Wiring Terminals

7. Panel Reset Switch

8. Network Terminator Jumper

9. Network Wiring Terminal Block

10. Digital Switch Port

11. Panel Communications Port

12. Peripheral Power Terminal: +24VDC, DC Ground

13. Switch Input Wiring Channels

14. Panel Network Address DIP Switches

Item Reference

The ControlKeeper-4 consists of a logic board with a clear separation of line-voltage and low voltage components. There are

several features of note on the logic board as pointed out in the below item reference diagram.

Page 7

PArt Number Here

All products manufactured by Cooper Controls and identiﬁed with the Greengate brand are warranted to be free from defects in material and workmanship and

shall conform to and perform in accordance with Seller’s written speciﬁcations for a period of :

• Five (5) years from date of shipment for all occupancy sensors.

• Three (3) years from date of factory invoice for our hardware and software on Lighting Control Panels.

• We warranty all our standard relays for a period of 10 years from date of factory invoice. We guarantee the performance of our system to speciﬁcations or your

money back.

This warranty will be limited to the repair or replacement, at Seller’s discretion, of any such goods found to be defective, upon their authorized return to Seller. This

limited warranty does not apply if the goods have been damaged by accident, abuse, misuse, modiﬁcation or misapplication, by damage during shipment or by

improper service. There are no warranties, which extend beyond the hereinabove-limited warranty, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTY

OF MERCHANTABILITY AND THE IMPLIED WARRANTY OF FITNESS.

No employee, agent, dealer, or other person is authorized to give any warranties on behalf of the Seller or to assume for the Seller any other liability in connection

with any of its goods except in writing and signed by the Seller.

The Seller makes no representation that the goods comply with any present or future federal, state or local regulation or ordinance. Compliance is the Buyer’s re-

sponsibility. The use of the Seller’s goods should be in accordance with the provision of the National Electrical Code, UL and/or other industry or military standards