Greengate ControlKeeper 2 CK2-120-NC Assembly instructions

ControlKeeper®2

INSTALLATION SHEET

Model # CK2-120-NC

Model # CK2-120-NO

Model # CK2-277-NC

Model # CK2-277-NO

General Information

The ControlKeeper-2®is shipped in one package and is

congured with a 120V transformer or a 277V transformer.

The two relays are mounted in the high voltage compart-

ment. The logic board and inputs are located in the low volt-

age compartment. The following information describes the

ControlKeeper-2® installation. For programming information,

refer to the Keeper Enterprise Software Manual.

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 service must be performed by qualied

personnel or service technicians.

5. Install in accordance with National Electrical Code and

any other codes that may apply.

6. High Voltage is present inside the lighting 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.

7. Document all wiring that is terminated to the relays so that

the lighting control equipment can be properly congured

and programmed for operation.

8. It is recommended that all low voltage wiring be done with

power removed to the logic board to protect components

from potential shorts during the wiring process.

Mounting the Enclosure

1. Choose a dry location convenient to the circuits being

controlled.

2. Mount the panel on a rm surface using predrilled holes.

3. Connect the enclosure to the circuit breaker panel using

conduit into the punch holes provided.

4. Remove all cuttings and dirt.

Note: Make certain that high voltage and low voltage

wiring enters the enclosure separately. High Voltage wir-

ing should be brought into the right section of the enclo-

sure. Low Voltage wire should enter in the low voltage

wiring compartment on the left side of the enclosure.

Failure to separate high voltage from low voltage wiring may

cause interference with logic board function.

Wiring the Transformer

The ControlKeeper-2® is factory congured with a 120V tran-

former or a 277V transformer. The transformer voltages are

color-coded. The 120V transformer has the power wired to

the black wire and the 277V transformer has the power wired

to the orange wire. The neutral is the white wire.

Connect wires to the transformer. You must provide a dedi-

cated circuit with circuit protection for the transformer.

Connecting Relay Loads

Relay Notes:

1. The standard relay is rated for single-pole load use only.

Connection of 2 pole circuits/loads to the relay will void the

equipment warranty and may result in severe injury or death,

and/or damage to the equipment.

2. Relay ratings are 120 or 277 volt, 20 amp maximum.

3. Relay terminal blocks have a maximum limit of 10AWG

wire.

RP7

GND

RN6

R13

SN1

MOV1

RELAY 2

R12

TF1

C64

C63

MOV6

C99

C100

SR1

C55

C56

C57

C58

C59

C50

C61

C62

C71

C10

C21

C51

C80

C83

D99

C81

C82

SN2

MOV2

U32

SD1

R71

R112

R111

R61

BR1

U45

RP2

C52

CH1

MOV7

RP1

U35

MOV9

J51

R54

U47

MOV8

R56

R57

U38

C18

U46

L34

R49

C53

C19

U37

C31

R48

U30

CX1

CX2

R6A

R6B

R7B

R7A

U36

C38

C36

C37

C39

OFF

+24

OFF

+24

CH2

54-020610-__

54-020611-__

54-020620-__

54-020621-__

RELAY 1

NETWORK

RESET

Low Voltage Compartment High V o ltage Compartment

120V T r ansformer

Line = Black

Neutral = White

277V T r ansforme

Line = Orange

Neutral = White

Line = 120V (Black),

277V (Orange)

Neutral = White

Transformer Wiring Information

High voltage and low voltage

wiring entering the enclosure

Cooper Controls

203 Cooper Circle, Peachtree, GA 30269

800-553-3879

www.coopercontrol.com

Relay Wiring

Note: Neutrals terminate within the adjoining lighting panel.

The standard relay is a simple contact closure, breaking the

line and load wires of a normal circuit.

To wire the relay into the control unit:

1. Verify that all wire cuttings are removed from the enclosure.

2. Test branch circuits for short circuits prior to landing wiring

on relays.

3. Connect a 120 or 277 volt, 20 amp max, de-energized

branch circuit breaker to the relay terminal block.

4. Connect the load wiring to the output terminal block. Note:

terminal blocks are not polarity sensitive although it is

recommended that line and load be brought into terminal

blocks in the same manner for consistency.

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

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

6. Document relay to circuit information for future reference.

ControlKeeper-2® Relay Wiring

Connecting Low Voltage Inputs

The ControlKeeper-2® logic board can support both dry contact

closure and Digita® Switch inputs. If a combination of contact

input switches and Digita® 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-2® panel, there may

be a limitation on the number of sensors that can be sup-

ported. This is also true if Digita® 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

devices. There are two switch input wiring terminals on the

left side of the ControlKeeper-2® 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-2® system.

ControlKeeper-2® Low Voltage Switch Wiring

Contact Input Photosensor and Greengate Sensor Notes

It is possible to use a contact input photosensor and Greengate

Motion Sensors in conjunction with the lighting control system.

The ControlKeeper-2® 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.

40 16 20 20

Greengate

PIR Sensor

Greengate

Dual-Technology

Sensor

Greengate

Ultrasonic

Sensor

PPS-4

Indoor

Photosensor

PPS-5

Outdoor

Photosensor

Page 2

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 Digita®

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

Digita®Switch Wiring

Each ControlKeeper-2® panel is capable of supporting up to 14

Digita® Switch device stations and 1 Digita® Switch Gateway (the

number the controller is able to support is dependent on the num-

ber 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.)

Digita® 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 as-

sistance, additional charges for support may be assessed.

Digita® Switches do not wire directly to the ControlKeeper-2®

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

ControlKeeper-2® through a Digita® Switch Gateway. Digita®

Switch devices should be networked together in a daisy chain

conguration. No T-Taps/Stars should be used. The Digita®

Switch Gateway device should reside somewhere within the

daisy chain switch network. Total daisy chain network length

should not exceed 1000 feet.

The following instructions describe the Digita® Switch Gateway

connection to the ControlKeeper-2®. Please refer to the Digita®

Switch Installation Instructions included with your Digita® Switch

Gateway for information on wiring the Digita® Switch network

to the Digita® Switch Gateway.

1. Mount the Digita® Switch Gateway next to the ControlKeep-

er-2® panel. A six foot phone style cable has been provided

for connection to the ControlKeeper-2® panel.

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

from the Digita® Switch Gateway location to the low voltage

section of the ControlKeeper-2®.

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

back of the Digita® Switch Gateway and to the Control

Keeper-2® at one of the switch input +24VDC terminals.

4. Connect the BLACK wire in the cable to the GND terminal

on the back of the Digita® Switch Gateway and to the Con-

trolKeeper-2® 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 Digita® Switch Gateway and lighting controller.

6. Locate the 6 foot phone style cable included in the Digita®

Switch Gateway box. Run this from the Digita® Switch

Gateway into the low voltage section of the ControlKeeper-2®

enclosure plugging the end that is labeled DIGITA into the

Digita® Switch Gateway. Plug the end that is labeled LIGHT

ING CONTROLLER into the ControlKeeper-2® RJ connec-

tor.

7. Ensure that the ControlKeeper-2® Option Select dipswitch 1

is in the on position to congure the ControlKeeper-2®to

accept the Digita® commands through its COM port.

Digita® Switch Wiring

Network Wiring Notes

The ControlKeeper-2® 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 back and forth as well as allows the system to be

programmed from one central location by a computer with the

Keeper Enterprise Software.

Page 3

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 as-

sistance, additional charges for support may be assessed.

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 ControlKeeper-2® panel.

5. If using Belden 9841 or 82841, leave all shields discon-

nected making certain that shield is not exposed. These

wire types will be connected to a special terminal block on

the right side of the controller.

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

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

end panels of the network and plan a wiring scheme accord-

ingly. Panels should be daisy chained, not Star or T-

tapped.

2. Pull the twisted pair wiring in conduit along the planned

route, making certain that it is separate from any high volt-

age wiring.

3. 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.

4. 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 termina-

tion jumper.

Network Addressing

Assign each panel a network address. A network address is re-

quired for the ControlKeeper-2® to communicate over a network

and for programming with the Lighting Control Software. A selector

switch is provided on the panel to assign the panel ID number.

Switch positions are labeled 1 through 8 and valued at 1 through

128. The ID # is calculated by adding the values of each position

that is ON. Addresses 1 through 254 are valid addresses. Zero

is not a valid address. In addition, address 255 is reserved for

system use and should not be used as a panel address.

Note: Each ControlKeeper-2® must have a unique address. If

networked with other ControlKeeper panels, each panel must

have a different address.

128

124816 32 64

12 643578

Switch

Position

Value

Standard CAT 5Belden 7854A

Belden 1583A

Belden 9841 (Shield is not used)

Belden 82841 (Shield is not used)

None Available

Belden 7811A

Belden 1585A

Contractwire.com CM1202L5-BBDN

General cable 2137113

General cable 2137114

LCOM TOBC2004

Mohawk/CDT M57042

Omni J162404-DB

Syndata.com 763108 Mfct: Helix

SuperiorEssex 04-001-34

Standard CAT5e

Plenum CAT5

Plenum CAT5e

Standard RS 485

Plenum RS 485

Direct Burial RS 485

Direct Burial CAT5

Acceptable

Lighting Network

Wiring

Suggested Cable

Page 4

To initialize the ID# within the ControlKeeper-2®, it is necessary

to do a reset. Press the panel-reset button located on the lower

left side of the panel after setting the panel address.

Applying Power

1. Once the wiring is complete, make certain that the enclosure

is clean of any wire clippings and that no fragments are

lodged in the relay circuit boards.

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

could short to other wires or components.

3. Power up the unit from the circuit breaker.

4. Once power is applied to the unit, lighting loads may be

operated via the ALL ON / AUTO / ALL OFF Switch as

necessary.

Manually Controlling Relays

The relays in the enclosure may be controlled before the logic

board is programmed by using the on-board, ALL OFF, AUTO,

ALL ON switches. In the ALL ON position the relay coils will

be energized. In the ALL OFF position, the relay coils will be

de-energized. The middle, AUTO, position allows the relays

to be controlled by the individual relay switches or from the

logic controller.

System Reset and Clear Commands

Under certain circumstances, you may want to reset the

ControlKeeper-2®. There are two different types of reset com-

mands available in the ControlKeeper-2® system: a soft reset

command and a clear reset command.

Soft Reset Command: The Soft Reset Command reboots

the microprocessor. It will not cause loss of panel program-

ming. To perform a Soft Reset Command, press and release

the reset button.

Clear Settings Command: A clear settings command is used

to remove all programming from a ControlKeeper-2® unit. It

should be done before 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 ALL ON

override switch to keep lighting on if necessary.

To perform a Clear Command: Press and hold the reset

button for at least 20 seconds. The status LED will start ick-

ering. Release the reset button. The unit is now cleared to

factory default programming.

LED Operation

The ControlKeeper-2® has LEDs mounted on the left side

of the panel. Refer to the diagram at the beginning of these

instructions for the location of these LEDs.

System LEDs

There are three (3) system status LEDs that are located in the

upper section of the ControlKeeper-2®. These status LEDs

will indicate proper operation or potential problems with the

ControlKeeper-2®. Normal Operation includes the following

LED states.

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

ously under normal operation.

Power LED: The Power LED is ON when power is applied

to the panel.

Network LED: The Network LED will ash when activity is

present on the network.

Relay Status LEDs

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

the ControlKeeper-2®. 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.

RS232 Port

The Lighting Control Software for programming uses the

RS232 phone-jack style communications port with a RJ12

connector. A special cable will be supplied with the software

program for connection to this port. In addition, other periph-

eral devices provided by Greengate may plug into this port for

communication purposes.

In ControlKeeper-2® units the RS-232 Port may be used for

Digita® Switches. In this conguration only, set the option se-

lect DIP Switch 1 to the ON position. With all other peripheral

devices, DIP Switch 1 on the option select switch should be

in the down (OFF) position for proper operation.

Programming the ControlKeeper-2®

The ControlKeeper-2® is programmed through the Keeper

Enterprise Software. Please refer to your Keeper Enterprise

Manual for programming details. It is recommended that a

Clear Settings Command be performed on the controller before

the rst programming is done 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-2® unit,

please refer all service to Greengate technical support line at

1-800-553-3879.

Page 5

Item Reference Drawings

1. DC Ground

(Do not connect to Earth or Conduit Ground)

2. Option Select Switch

3. Switch Input Channels

4. RS232 – RJ12 Connector

5. Network Terminal

6. Network Termination Jumper

7. Panel ID Selection Switch

8. System Status LEDs

9. Relay 1 Override Switch

10. Relay 1 Status LED

11. High/Low Voltage Barrier

12. Relay Output 1

13. 120V (Black) or 277V (Orange)

14. Neutral (White)

15. Transformer

16. Relay Output 2

17. Relay 2 Override Switch

18. Relay 2 Status LED

19. Reset Switch

Page 6

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 of 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