COOPER K2-120NO ControlKeeper 2 Lighting Solution Instruction Manual

COOPER K2-120NO ControlKeeper 2 Lighting Solution

General Information

The Control Keeper 2 is shipped in one package and is configured with a 120V transformer or a 277V transformer. The two relays are mounted in the high voltage compartment. The logic board and inputs are located in the low voltage compartment. The following information describes the Control Keeper 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 qualified 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 configured 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 firm surface using pre-drilled 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 wiring should be brought into the right section of the enclosure. 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 Control Keeper 2 is factory configured with a 120V transformer 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 dedicated 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 10 AWG wire

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

6. Document relay to circuit information for future reference.

Connecting Low Voltage Inputs

The Control Keeper 2 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 combined 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 volt age wiring must enter the cabinet into the low voltage section of the enclosure. Low volt age wiring can be brought into the enclosure from the left side of the enclosure. Failure to separate high volt age from low voltage wiring may cause interference with logic board function.
3. All low voltage wiring must be r un in separate conduit from line voltage wiring.
4. Test all low voltage wiring for shorts to A C ground before connection to the relay panel.
5. When powering peripheral devices such as motion sensors and photosensors from the Control Keeper 2 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 Lighting Solutions 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 Control Keeper 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 Control Keeper 2 system.

Control Keeper 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 Control Keeper 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.

Greengate PIR Sensor

| Greengate Dual-Technology 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 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.

Digital Switch Wiring

Each Control Keeper 2 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 LC 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 Control Keeper 2 panel, but are wired to a CAN Bus network that connects to the Control Keeper 2 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 Control Keeper 2. Please refer to the GDS installation instructions for information on wiring the digital switch network to the Digital Switch Gateway.

1. 1. Mount the GDS-I next to the Control Keeper 2 panel. A six foot phone style cable has been provided for connection to the Control Keeper 2 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 Control Keeper 2.
3. Connect the RED wire in the cable to the +V terminal on the back of the GDS-I and to the Control Keeper 2 at one of the switch input +24 VDC terminals.
4. Connect the BLACK wire in the cable to the GND terminal on the back of the GDS-I and to the Control Keeper 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 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 Control Keeper 2 enclosure plugging the end with pin head into the GDS-I. Plug the end of theRJ11 phone style plug into the Control Keeper 2.
7. Ensure that the Control Keeper 2 option select DIP switch
   1 is in the ON position to configure the Control Keeper
   2 to accept the digital switch commands through its communications port.

Network Wiring Notes:

The Control Keeper 2 is designed to communicate with other Control Keeper 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.

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.

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 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 Control Keeper 2 panel.

5. If using Belden 9841 or 89841, 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:

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 termination jumpers on the panel. If the panel is wired as the beginning or end devicesin the network place the termination jumper over the provided termination pins. If the panel is not at the beginning or end of the network, remove the jumper from the provided termination pins.

Network Addressing

Assign each panel a network address. A network address is required for the Control Keeper 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 Control Keeper 2 must have a unique address.
If networked with other Control Keeper panels, each panel must have a different address.

To initialize the ID# within the Control Keeper 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 Control Keeper 2. There are two different types of reset commands available in the Control Keeper 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 programming. 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 Control Keeper 2 unit. It should be done before programming 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 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 flickering. Release the reset button. The unit is now cleared to factory default programming.

LED Operation
The Control Keeper 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 Control Keeper 2. These status LEDs will indicate proper operation or potential problems with the Control Keeper 2. Normal Operation includes the following LED states.

Status LED:
The Status LED will flash ON and OFF continuously under normal operation.

Power LED:
The Power LED is ON when power is applied to the panel.

Network LED:
The Network LED will flash when activity is present on the network.

Relay Status LEDs

There are two relay status LEDs, one for each of the relays on the Control Keeper 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 peripheral devices provided by Greengate may plug into this port for communication purposes.

In Control Keeper 2 units the RS-232 port may be used for Digita® Switches. In this configuration only, set the option select 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 Control Keeper 2
The Control Keeper 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 first 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 Control Keeper 2 unit, please refer all service to Greengate technical support line at 1-800-553-3879

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

WARRANTIES AND LIMITATION OF LIABILITY

Please refer to www.cooperlighting.com under the Legal section for our terms and conditions.

Customer Support

Cooper Lighting Solutions
1121 Highway 74 South
Peachtree City, GA 30269
P:770-486-4800
www.cooperlighting.com
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All Rights Reserved
Printed in USA
P/N: 9850-000229-01
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