Greengate ControlKeeper 4 Installation Manual
Installation Instructions
ControlKeeper 4
Model# CK4-120NO
Model# CK4-277NO
INS #
General Information
The ControlKeeper 4 model is shipped in one package and
is configured with either a 120V or a 277V transformer. It
is factory configured 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
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 4 cabinet using the
holes provided 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.
Bring low voltage in
through the Left Side
of the Enclosure
Figure 1. ControlKeeper 4 Enclosure
Bring high voltage in
through the Right Side
of the Enclosure
Power Supply Wiring
The ControlKeeper 4 is factory configured 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.
General Information
Netural=White
Netural=White
Line=120V (Black)
277 (Orange)
Netural=White
120V Transformer
Line=Black
277V Transformer
Line=Orange
Figure 2. 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-energized branch circuit breaker to the relay terminal
block position labeled LINE.
5. Connect the load to the output terminal block position
labeled LOAD.
6. Tighten down relay terminal screws. Manufacturer’s
recommended torque rating is 7 lbs-in. (0.59 lbs-foot)
(0.8Nm).
Relay Wiring
Wire: 10 AWG Max
Relay Rating: 20 amps, 277V
RELAY 1
LINE
LOAD
LINE
From Branch Circuit
To Lighting Load
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
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 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 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
connecting 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 configuration.
Suggested Cable
LOAD
RELAY 2
LINE
LOAD
RELAY 3
LINE
RELAY 4
LOAD
Figure 3. Address Switch Information
ote:N Neutrals terminate within the adjoining lighting panel.
2
ControlKeeper 4
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 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.
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
identification 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.
General Information
RS232 DIGITA NETWORK
Network Wiring
Terminal Block
Figure 5. Item Reference for Network Details
Switch
Position
Value
Network
Address
Switch
Panel
Reset
Switch
Network
Termination
Jumper
ON
OFF
End Panel
Network Wiring
Detail
Middle Panel
Network Wiring
Detail
End Panel
Network Wiring
Detail
Figure 4. Network Wiring Detail
Termination
Jumper ON
Termination
Jumper OFF
Termination
Jumper ON
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 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 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.
ControlKeeper 4
3
General Information
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
devices. 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.
Momentary Switch
(3 wire)
Toggle Switch (2 wire)
C20
U21
C26
U26
RN1
TB4
ON
+24VDC
OFF
Maintaned Switch (2 wire)
+24
OFFON
CH1
ON
+24VDC
ON +24
+24VDC
CH2
U17
U18
U19
U24
U23
U22
U27
41235687
U29
ON +24
ON +24
OFF
OFF
CH4
CH3
ON
U28
TB5
+24
OFF
VDCDCGND
U20
U25
J2J1
S7
RESET
NET TERM
TB7
J3
-+
NETWORKDIGITARS232
Figure 7. 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.
Greengate
PIR Sensor
Greengate
Dual-Technol
Greengate
Ultrasonic
Sensor
PPS-4
Indoor
Photosensor
40 16 20 20 4
Please contact technical support if it is necessary to power
PPS-5
Outdoor
Photosensor
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.
Black
ON
+24VDC
(Red Wire)
Yellow & White
Wires Not Used
PPS4
Black
PPS5
Black
Black
Typical Greengate
iW kcalB(
er
)
DNG CD RWP MER
Contact Input
Photosensor
Wiring
ON
(Blue
Wire)
(White Wire)
+24VDC
(Red Wire)
(Blue Wire)
+24VDC
(Red Wire)
ON
Motion Sensor
Wiring
Figure 8. 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 Eaton’s 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 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 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
4
ControlKeeper 4
General Information
Individual Relay
Override Switches
Hardware Override Switch
ControlKeeper® 4 Upper Left Corner
configuration. 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
connection 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
connectionto 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
terminal 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.
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.
C20
U21
C26
U26
RN1
U29
TB4
+24
ON +24
OFFON
CH2
CH1
BLACK Wire From GDS-I
GND to CK4 GND
RED Wire From GDS-I V
+ to CK4 +24VDC
Cabling is Eaton’s Cooper LC Cable,
Belden 1502R, or Belden 1502P
Figure 9. GDS-I Wiring Detail
U17
U18
U23
U22
U27
U28
TB5
ON +24
ON +24
OFF
OFF
OFF
+24
VDCDCGND
CH4
CH3
U20
U19
U24
U25
41235687
J2J1
S7
RESET
NET TERM
TB7
J3
-+
NETWORKRS232
Wire Phone Style Cable to
RJ11 Jack on CK4 and to GDS-I
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
GDS-I
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
ControlKeeper 4
5
General Information
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.
ControlKeeper® 4 Upper Left Corner
Digita Switch
Status Power Network
System Status LEDs
Relay Status LEDs
Relay 1 Through 4
Figure 11. 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
Figure 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 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.
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
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 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.
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
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 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 initialize 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 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 in
the lower right corner of the logic panel. When the reset
button is pressed and released, the status LED may hesitate
briefly 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 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 in the lower right
corner of the low voltage section for a period of 15 seconds
6
ControlKeeper 4
General Information
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
first programming download to clear any test data that may
be left in the controller from factory testing.
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.
2
3
4
1
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.
5
14
Figure 12. 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
6
78910111213
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: +24 VDC, DC Ground
13. Switch Input Wiring Channels
14. Panel Network Address DIP Switches
ControlKeeper 4
7
Renseignements généraux
Renseignements généraux
Le modèle ControlKeeper 4 est livré en une seule boîte et
est doté d’un transformateur soit de 120V soit de 277V.
Il est configuré en usine et est muni de relais normalement
ouverts. Pour connaître le type de modèle en votre
possession, consultez votre commande.
Pour commencer
1. Ne jetez pas ces instructions d’installation. Veuillez les
conserver pour une référence ultérieure.
2. Débranchez toujours toutes les alimentations
électriques avant de procéder au câblage.
3. Utilisez uniquement aux fins prévues et à la tension
indiquée.
4. L’installation, les réparations et l’entretien doivent être
effectués par des techniciens en entretien et réparation
ou par du personnel qualifié.
5. L’installation doit se faire conformément au Code
national de l’électricité et à tout autre code applicable.
6. Les renseignements sur l’installation et le câblage qui
sont fournis dans ce document sont fondés sur des
normes et des pratiques reconnues dans l’industrie.
Si ces instructions vont à l’encontre de codes ou de
règlements applicables, veuillez communiquer avec
Greengate avant de commencer l’installation.
7. Une haute tension est présente dans le boîtier. Prenez
des précautions extrêmes lorsque vous effectuez
l’entretien de cet équipement. Le non-respect de cet
avertissement et des procédures de sécurité
appropriées peut entraîner des blessures sérieuses
ou la mort et/ des dommages à l’équipement.
8. Pour vous aider à configurer et à programmer les
dispositifs par la suite, prenez en note l’emplacement
de ces derniers et des connexions.
Faire passer les ls à basse
tension par le côté gauche
du boîtier
Faire passer les ls à haute
tension par le côté droit du
boîtier
Figure 1. Boîtier du ControlKeeper 4
Câblage de l’alimentation
Le modèle ControlKeeper 4, configuré en usine, est doté
d’un transformateur de 120V ou de 277V. Les tensions du
transformateur sont codées par couleur. Il est conseillé de
réserver un circuit de dérivation avec protection des circuits
à l’utilisation du câblage du bloc d’alimentation.
1. Connectez le câble neutre au câble blanc.
2. Si le transformateur de votre appareil est de 277V,
brachez le fil orange à un circuit de 277V. Si le
transformateur de votre appareil est de 120V, branchez
le fil noir à un circuit de 120V.
Ligne = 120V (noir),
277 (Orange)
Neutre=blanc
Montage de l’armoire électrique
1. Choisissez un endroit sec sur une surface dure, proche
des circuits à commander. Prévoyez un dégagement
suffisant pour l’ouverture complète de la porte.
2. Montez l’armoire ControlKeeper 4A à l’aide des trous
ménagés au dos du boîtier. Il est recommandé
d’assembler le panneau à la verticale.
3. Tous les conducteurs à haute tension doivent pénétrer
dans l’armoire par le côté droit du boîtier.
4. Tous les conducteurs à basse tension doivent pénétrer
dans l’armoire par le côté gauche du boîtier.
5. Dégagez tous les débris et les rognures de métal du
boîtier avant de mettre le ControlKeeper 4 sous tension.
8
ControlKeeper 4
120V Transformateur
Ligne=noir
Neutre=blanc
277V Transformateur
Ligne=Orange
Neutre=blanc
Figure 2. Boîtier du ControlKeeper 4
Branchement des charges du relais
1. Effectuez un essai des circuits de dérivation pour
des courts-circuits avant de brancher et de mettre le
ControlKeeper 4 sous tension.
2. Les borniers des relais ont une limite maximum de
3. 10 AWG pour le câblage.
4. Les relais sont destinés à être utilisés avec les
circuits unipolaires seulement. Le branchement
du ControlKeeper 4 à des circuits ou des charges
bipolaires annulera la garantie de l’appareil.
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