COOPER Lighting Solutions CK4A-SSRC ControlKeeper 4A Instruction Manual

COOPER Lighting Solutions CK4A-SSRC ControlKeeper 4A

Product Information

The product is the ControlKeeper 4A, available in three models:
CK4A-SSRC, CK4A-SLRC, and CK4A-STPRC. It is an electrical control cabinet used for controlling circuits.

Installation Instructions

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 qualified 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 manual must be strictly followed.

Mounting the Cabinet

1. Choose a dry location on a firm surface convenient to the circuits being controlled. Allow full clearance for the door of the enclosure to open fully.
2. Mount the ControlKeeper 4A cabinet using the holes provided in the back of the enclosure.
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 4A.

Note: Make certain that high voltage and low voltage wiring enters the enclosure separately. Failure to separate high voltage from low-voltage wiring may cause interference with functionality.
High Voltage wiring should not be brought into the enclosure through the left side of the enclosure. Low voltage wiring can be brought into the enclosure from the bottom left or upper left of the enclosure. Due to limited space on the left side of the enclosure, it is recommended that connections be brought through the top or bottom of the enclosure for the low-voltage wiring.

Power Supply Wiring

The ControlKeeper 4A contains a multi-tapped transformer that is available in 120V/277V/347V 60 Hz or 230V/240V 50 Hz models.
Voltages are color coded. It is recommended that a dedicated branch circuit with circuit protection be provided for the transformer.

1. Connect neutral wire to the wire with the appropriate color coding for the voltage being used: See Transformer Color Chart on page 2 for Neutral Connections by voltage.

Model# CK4A-SSRC
Model# CK4A-SLRC
Model# CK4A-STPRC

Installation Instructions

ControlKeeper® 4A

General Information

The ControlKeeper 4A model is shipped in one package and is configured with a dual tapped 120V/277V/347V 60 Hz or 230V/240V 50 Hz transformer. It can be configured with different relay types as needed to achieve lighting needs. Please refer to your order information to determine which model you have purchased.
The ControlKeeper 4A can control up to four relays per panel with optional support for up to four 0-10V dimming control outputs to allow for combinations of relay switching and load dimming.

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 qualified 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 document is based on industry-accepted standards and practices. If conflicts 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 locations so that devices can be properly configured and programmed for operation.

Mounting the Cabinet

1. Choose a dry location on a firm surface convenient to the circuits being controlled. Allow full clearance for the door of the enclosure to open fully.
2. Mount the ControlKeeper 4A cabinet using the holes provided in the back of the enclosure.
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 4A.

Note: Make certain that high voltage and low voltage wiring enters the enclosure separately. Failure to separate high voltage from low-voltage wiring may cause interference with functionality. High Voltage wiring should not be brought into the enclosure through the left side of the enclosure.

Low voltage wiring can be brought into the enclosure from the bottom left or upper left of the enclosure. Due to limited space on the left side of the enclosure, it is recommended that connections be brought through the top or bottom of the enclosure for the low-voltage wiring.

Power Supply Wiring

The ControlKeeper 4A contains a multi-tapped transformer that is available in 120V/277V/347V 60 Hz or 230V/240V 50 Hz models. Voltages are color coded. It is recommended that a dedicated branch circuit with circuit protection be provided for the transformer.

1. Connect neutral wire to the wire with the appropriate color coding for the voltage being used: See Transformer Color Chart on page 2 for Neutral Connections by voltage.
2. Connect the solid black wire to the dedicated branch circuit that is powering the transformer.

Transformer Color Chart

Connecting Relay Loads
The relay cards will be pre-mounted by the manufacturer in the enclosure per the order specifications.
There are currently three available relay types for the ControlKeeper 4A enclosure. This includes the Serial Standard Relay Card, the Serial Two Pole Relay Card and the Serial Latching Relay Card. Please refer to the specific section for the relay card type that you are wiring. For all relay types:

1. Verify that all wire cuttings are removed from the enclosure.
2. Take the protective shrink wrap off of the relay cards once the wire cuttings are removed from the enclosure.
3. Test branch circuits for short circuits prior to landing wiring on relays.
   Note: Neutrals terminate within the adjoining lighting panel.

Standard Relay Card Notes

1. The Standard Relay Card is rated for single-pole load use only. Connection of 2 pole circuits/loads to the Standard Relay Card 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.
   Standard Relays are available in a Normally Open configuration.

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

Standard Relay Card Wiring
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 circuit:

1. Connect a 120 or 277 volt, 20 amp max, de-energized branch circuit breaker to the relay terminal block position labeled LINE.
2. Connect the load wiring to the output terminal block position labeled LOAD.
3. Tighten down relay terminal screws. Manufacturer’s recommended torque rating is 7 lbs-in. (0.59 lbs-foot) (0.8Nm).
4. Document relay to circuit information for future reference.

Latching Relay Card Notes

1. The Latching Relay Card is rated for single-pole load use only. Connection of 2 pole circuits/loads to the Latching Relay Card will void the equipment warranty and may result in severe injury or death, and/ or damage to the equipment.
2. Relay ratings are 120/277/347 volt, 20 amp maximum.
3. Relay terminal blocks have a maximum limit of 8 AWG wire.

Latching Relay Card Wiring
The latching relay is a simple closure, breaking the line and load wires of a normal circuit. To wire the relay into the control circuit:

1. Connect a 120, 277 or 347 volt, 20 amp maximum, de-energized branch circuit breaker to the relay terminal block position labeled LINE.
2. Connect the load wiring to the output terminal block position labeled LOAD.

Two Pole Relay Card Notes

1. Two Pole Relay ratings are 208/240/480 volt, 20 amp maximum.
2. Relay terminal blocks have a maximum limit of 8 AWG wire.
3. Two Pole Relays take up two relay slots in the enclosure.
4. Two Pole Relays come in a Normally Open or Normally Closed configuration.

Two Pole Relay Card Wiring

1. Connect one de-energized branch circuit breaker to one of the relay terminal block LINE location.
2. Connect the load side to the output terminal block position of this same terminal block, labeled LOAD.
3. Connect the other de-energized branch circuit breaker to the other relay terminal block’s LINE location.
4. Connect the second load wire to the second terminal block, labeled LOAD.
5. Tighten down relay terminal screws. Manufacturer’s recommended torque rating is 18 lbs-in. (1.475 footlbs) (2.0Nm).
   Document relay to circuit information for future reference.

Network Wiring Notes

The ControlKeeper 4A 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.
For best network performance, Belden 9841 or 89841 should be used. If the specified 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 into the
   Low voltage section of the enclosure. Low Voltage wiring can be brought into the enclosure from the bottom left or top left 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 network wiring for shorts to AC ground before connecting to the ControlKeeper 4A panel.

5. Leave all shields disconnected 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 configuration.

7. Total network length should not exceed 4000 feet.

Network Wiring Detail

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. Pull the twisted pair wiring in conduit along the planned route, making certain that it is separate from any high voltage 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 finished, 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 termination jumper.

5. Set all panel addresses using the panel network identification dip-switches on each panel. See Figures 6 & 7 for location and details.

6. Using the panel reset switch, issue a soft reset to each panel to initialize the panel address. See Figure-6 for location of the reset switch.
   See Figures 5-7 on the next page for a picture reference of twisted pair network wiring and for item reference of network wiring components.

Note: 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 value 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 rest button after the address is set.

Dimmer Wiring Information

There are four Dimming Output channels at the bottom of the ControlKeeper 4A that allow for connection to 0-10V dimming ballasts. Up to fifty 0-10V ballasts may be controlled off of one dimming output channel.
Please wire the ballast 0-10V wiring per the manufacturer’s specification. Before connecting the ballast 0-10V wires to the ControlKeeper 4A, please run the following test.
Touch the two 0-10V wires together, the dimming ballasts should go full low. When you disconnect these wires, the dimming ballasts should go full bright. If the ballasts do not perform properly, there is a miswire or problem with one of the ballasts wired. Do not connect the ballasts to the Greengate system until this test proves operational.

1. Perform the test outlined in the paragraphs above prior to connection.
2. Terminate the 0-10V wires at the bottom left corner of the ControlKeeper 4A on the terminal strip labeled Dimming Outputs. Each of these output channels is labeled VIO and GRY. This stands for the violet and gray wiring that is standard for these types of ballasts. Please match wire color to the terminal. If the lighting load is also being switched by a relay, it is recommended that the relay number and the channel number for the dimmer output match.

Connecting Low-Voltage Inputs

Analog Input Wiring
This section describes the wiring for analog input devices.
There are four analog input wiring terminals on the left side of the ControlKeeper 4A to allow for wiring of the analog input devices. Analog Input devices must have a 0-10 VDC output for use with these channels. Please refer to the documentation that came with your device for information on proper placement and installation of the device. Proper placement is critical to system function. These instructions describe the wiring of the device at the panel end assuming that the devices are analog photo sensors that have been purchased from Greengate. Please contact technical support if you are using a device not purchased from Greengate to verify compatibility and wiring to the Greengate system.

1. Use 18 AWG twisted, unshielded wire for all low voltage analog input device wiring.
2. Maximum length for analog input device wiring is 500 feet.
3. Wire the signal wire (yellow wire) to one of the terminals labeled AN1, AN2, AN3, or AN4.
4. Wire the ground wire (black wire) to the corresponding COM channel located below the Analog signal channels.
5. Wire the +24V wire (red wire) to the peripheral power connector +24V supply.
6. Ensure that the local remote jumpers have been moved to the local position (over the top 2 pins) for both jumpers (J7 & J8) to enable 24VDC to the low voltage switch channels. See Figure 9 for location.
7. Please see wiring detail in Figure 9 for details on connections of a Greengate provided analog photosensor to the ControlKeeper 4A system.

Contact Input Switch Wiring
This section describes the wiring for dry contact closure devices. There are contact input terminals on the left side of the ControlKeeper 4A to allow for wiring of the dry contact closure devices. If a two-wire maintained or toggle type contact is used, up to eight inputs may be wired. If a 3-wire momentary closure is used, up to four inputs may be wired.
If using two wire devices, the IN terminal will be the ON wire termination point. The +24V terminal may be shared between two wired devices. If using three wire devices, the ON wire will wire to one IN terminal, the +24V will wire to the +24V terminal and the OFF wire will wire to a second IN terminal.

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. Ensure that the local remote jumpers have been moved to the local position (over top pins) for both jumpers (J7 & J8) to enable 24VDC to the low-voltage switch channels. See Figure 10 below for location.
4. Please see wiring detail in Figure 10 for details on connections of different devices to the ControlKeeper 4A system.

Figure 10: ControlKeeper 4A Low-Voltage Switch Wiring

Lighted Switch Notes

The ControlKeeper 4A has up to four input channels that allow for connection of a pilot light wire from a lighted switch. The terminals are labeled LS on the logic board.

Please see Figure 10 above referring to the Pilot Light  Momentary Switch for wiring example.

1. You must use Lighted Switches that have been approved for use with the ControlKeeper 4A system.
2. You can have no more than 20 LED lighted switches in a ControlKeeper panel, with no more than 6 LEDs per input channel.
3. You can have no more than 10 INCANDESCENT lighted switches per panel, with no more than 3 bulbs per input channel.
4. Please note that these figures may decrease if motion sensors, photosensors or digital switches are being used with the controller. In addition, if switch types are mixed (incandescent and LED being used on the same controller), these figures will change. Please contact Technical Support with the numbers and types of inputs you are using to determine if the controller will be able to support them without overloading the power supply.

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 4A 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.

Greengate PIR

Sensor

| Greengate Dual-Tech Sensor| Greengate Ultrasonic Sensor| PPS-4

Indoor Photosensor

| PPS-5

Outdoor Photosensor

---|---|---|---|---
40| 16| 20| 20| 4

Please contact technical support if it is necessary to power additional sensors beyond the numbers listed above.
These figures do not account for additional devices such as lighted switches or 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.

Digital Switch Wiring

Each ControlKeeper 4A 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 Lighting Solutions’ Cable, Belden 1502R (non-plenum), or Belden 1502P (plenum).
For best network performance, one of the suggested cables should be used. If the specified cable is not used and communications problems occur that require troubleshooting assistance, additional charges for support may be assessed.

Digital Switches do not wire directly to the ControlKeeper 4A panel, but are wired to a CAN Bus network that connects to the ControlKeeper 4A through a GDS-I device. Digital Switch devices should be networked together in a daisy chain configuration. No T-Taps/Stars should be used.
The GDS-I 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 GDS-I device connection to the ControlKeeper 4A. Please refer to the Digital Switch Installation Instructions for information on wiring the Digital Switch network to the GDS-I device.

1. Mount the GDS-I next to the ControlKeeper 4A panel.
   A six foot phone style cable has been provided for connection to the ControlKeeper 4A 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 4A.

3. Connect the RED wire in the cable to the +V terminal on the back of the GDS-I and to the ControlKeeper 4A remote power connector +24 V terminals.

4. Connect the BLACK wire in the cable to the GND terminal on the back of the GDS-I and to the ControlKeeper 4A 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 4A enclosure plugging the end with 9 pin head into the GDS-I. Plug the end the RJ11 phone style plug into the ControlKeeper 4A.

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. Power up the unit.
4. 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 4A.

Relay Override Operation
The ControlKeeper 4A 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.

Individual Relay Override Notes
Each relay on the ControlKeeper 4A may be overridden using the individual relay override switches located on the relay card on the right side of the enclosure. See Figure 13 for location of these switches. These override switches will toggle the associated relay’s state with each push of the button. This type of override is temporary in that the override will last until the next command to the relay. This override does not command the dimmers.

ALL OFF/AUTO/ALL ON Switch Notes
In addition to the individual relay override switch, 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. The dimmer channel will also be overridden to full bright in the ALL ON position. See Figure 13 for location of the hardware override switch.

LED Operation
The ControlKeeper 4A has LEDs for status monitoring.
These are explained below.

Network LED:
The Network LED should flash only when activity is present on the network wire. If communications commands are not being transmitted over the network wire from the Keeper Enterprise Software or broadcast switches and this LED is flickering, ON constant, or flashing, 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.

Override Switch Indicator LEDs:
The Override Switch Indicator LEDs will be lit if the ALL OFF/AUTO/ ALL ON Switch has been placed in the ALL ON or ALL OFF position.

Digital Switch LEDs:
These LEDs, labeled CAN-TX and CAN-RX, will flash when Digital Switch information is being passed back and forth between the Digital Switch Gateway and the ControlKeeper 4A.

Microprocessor Status LED:
The Status LED will flash ON and OFF continuously 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 flashing state, contact Technical Support.

Individual Relay Status LEDs:
Here are four relay status LEDs, one for each of the relays on the ControlKeeper 4A. Please refer to Figure 14 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.

Power LEDs:
This LED indicates that the ControlKeeper 4A is getting the proper expected voltage from the transformer. If this LED is not lit, there is a problem with power to the board. Please contact Technical Support for further details.

Input Communications Status LED:
This LED indicates that the input chips are in normal operation. These LEDs should flash to indicate system normal status.

Relay Communications Status LED:
This LED indicates that the relay communications chips are in normal operation. These LEDs should flash to indicate system normal status.

ControlKeeper 4A RS232 Port
The ControlKeeper 4A has an on board RS232 port for communications 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 ControlKeeper 4A. There are two different types of reset commands available in the ControlKeeper 4A system: a soft reset command and a clear reset command.

Soft Reset Command:
A soft reset command is used to initialize a new panel address with the panel. If can also be used as a troubleshooting technique if the panel is not responding or to free up the microprocessor if the unit’s Microprocessor Status LED is not flashing. 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. (Refer to Figure 15 for location of the reset switch.) When the reset button is pressed and released, the status LED may hesitate briefly then resume normal operation.

Reset Communications Switch:
In some situations it may be desirable to just cause a reset to the input and relay communications chips. This can be done using the reset button for this purpose in the middle of the board. It is recommended that you contact Technical Support prior to issuing this type of reset command.

Clear Settings Command:
A clear settings command is used to remove all programming from a ControlKeeper 4A unit. It should be done before downloading programming to the unit for the first 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 (first button on left) while pressing and releasing the clear button (middle button). Let go of the reset button. The ControlKeeper 4A unit will be cleared of all programming.

Programming the ControlKeeper 4A
The ControlKeeper 4A is programmed using Keeper Enterprise Software. Please refer to the Keeper Enterprise Manual for programming details. Unless pre- programmed by the factory, it is recommended that a Clear Command be performed on the controller before the first 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 4A unit, please refer all service to Greengate’s technical support line at 1-800-553-3879. The ControlKeeper 4A contains no user serviceable parts.

Operation Notes
The ControlKeeper 4A consists of a logic board, transformer and relay card. There are several features of note as pointed out in the item reference diagram on the next page.

1. Network LED
2. ALL ON LED
3. Panel Hardware Override Switch (ALL OFF, AUTO, ALL ON)
4. ALL OFF LED
5. Panel Addressing Switch
6. Digital Switch LEDs
7. Panel reset switch
8. Status LEDs
9. Relay Card connector
10. Relay override switch
11. Relay wiring terminal block
12. Transformer Wiring Leads
13. Transformer
14. Power LED
15. Transformer secondary power connection
16. Local remote jumpers
17. Peripheral power terminal: +24VDC, DC Ground
18. Relay PIC Status LED
19. Switch PIC Status LED
20. PIC Reset Switch
21. Switch Input Wiring Channels
22. 0-10V Dimmer Wiring Channels
23. Analog Photosensor Wiring Channels
24. Network Termination Jumper
25. Network Wiring Terminal Block
26. Network Wiring RJ Connections (CAT5 only)
27. Digital Switch Port
28. RS-232 Communications Port

WARRANTIES AND LIMITATION OF LIABILITY
Please refer to www.cooperlighting.com under the Legal section for our terms and conditions.

Cooper Lighting Solutions
1121 Highway 74 South
Peachtree City, GA 30269
P:770-486-4800
www.cooperlighting.com

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