EATON CG Controller

EATON CG Controller Controller

Basic specifications and compliance requirements

Application and positioning: CG Controller is a dedicated monitoring/controller for emergency lighting systems, which can control up to 32 sets of CG 2000 or ZB-S systems of the same type per unit. It belongs to building/enterprise safety equipment and is only allowed to be operated by professionals. Unauthorized operation may cause lighting system failure and safety accidents.

Compliance standards: The product complies with VDE 0108/10.89, DIN/VDE 0805/11.93, IEC 950 standards, developed/produced/tested according to DIN EN ISO 9001, meets the EU EMC Directive (89/336/EEC) and Low Voltage Directive (73/23/EEC), and has CE certification.

Core security requirements

The equipment must operate in a undamaged and fault free state;

All operations require disconnecting the system power supply and distinguishing between normal/emergency mode power supply;

Before operation, the emergency lighting system must be tested according to the installation instructions;

Comply with the safety regulations and accident prevention requirements of the host country, and report and rectify any malfunctions immediately.

Core technical parameters

The key technical parameters of the controller are hard operating indicators that cannot be deviated from without special instructions, as shown in the following table:

Specific project parameters

Supply voltage 230 V AC ± 10% or 24 V DC

Maximum power consumption 230V: 80mA; 24V：450mA

Alarm contact 1 × UM, 24V 0.5A, freely programmable

Communication interface LON FTT 10A interface card, CG-S BUS bus

Display module 4 × 20 characters with backlit alphanumeric LCD

Security/Protection Level Security Level II, IP 65

Working environment temperature: -5 ℃~+40 ℃; Humidity: 0-95% (no condensation)

The maximum compatibility of the wiring terminal is 2.5mm ² wire

Physical specification weight: approximately 1.8kg; size: 184 × 240 × 112mm (length × width × depth)

Installation and initial setup

The installation process is simple and supports two fixed methods. After completing the wiring, basic parameter configuration is required. The core steps are:

Assembly method: ① Drill holes and fix according to the drawing, and tighten the screws with just fingers; ② Can be directly installed on a 35mm DIN rail.

electrical connection

Power wiring: Complete 230V AC/N/PE or 24V DC wiring according to the diagram, equipped with freely programmable floating contacts;

Bus wiring: The BUS bus of the emergency lighting system must be connected to the A (2) B (2) terminals of the controller, with each input containing 4 terminals.

Initial necessary settings

After turning on the power, first set the current time and date, and confirm with the Menu/ENTER key;

Enter Menu → Setup Device → Find device autoim to complete the automatic registration of emergency lighting equipment;

Calibrate all system clocks to ensure accurate logging time.

Operation core: buttons, display and status/fault priority

The controller completes all operations and status visualization through physical buttons, LCD display screen, and LED indicator lights. The operation logic is clear, and status/faults are displayed according to priority:

Key definition: The core keys are Menu, ENTER, up and down (/), left and right (/) keys, each with multiple functions. For example, the Menu key can return to the main screen/previous menu, the ENTER key can confirm/open submenus, and the up and down keys can select menus/adjust values.

Dual display system

LCD display screen: 4 lines display, including software version, status, fault, time and date; Automatically return to the main screen after 3 minutes of no button operation, and the backlight will light up for 3 minutes after the button is triggered;

LED indicator light (front panel): green=normal operation, yellow=test mode, red=fault status. A single light on indicates that the corresponding status is in effect.

Priority of status display (from high to low): DT operation>FT operation>lockout>battery operation>UV-A mains fault>deep discharge protection>manual reset>DLS/TLS fault. High priority status will override low priority status and restore the original status after disappearing.

Fault display priority (from high to low): Device communication fault>Device mains fault>UV S3/S4 mains fault>UV RS485 mains fault>Total fault>Transmission fault>Battery fault>Converter fault>Charging/isolation fault>Lamp fault>Minimum duration fault.

Total fault: defined as the simultaneous occurrence of ≥ 2 types of faults, including 8 types of faults such as battery interruption, charging module failure, communication failure, and lighting failure. Individual faults do not trigger total faults.

Core menu functions

All operations of the controller are completed through the main menu → sub menu hierarchy. The main menu includes Test、Block/reset、Info device、Setup CG-Controller、Setup device、Memory Card  The six core modules have the following functions:

Test "menu: The core is emergency lighting system testing, supporting functional testing (FT) and duration testing (DT). It can start FT/DT for single/all devices, or cancel the running DT test. The test is confirmed to start by pressing the ENTER key.

<Block/reset>menu: ① Block all/Release all: One click lock/release all devices, select and execute immediately; ② Manual reset: After a mains power failure, manually reset the device one by one, and automatically exit the menu when there are no devices to be reset.

Menu "Info device": System status monitoring core, supporting viewing of device status, fault information, circuit status, lighting status, DLS/TLS/3PhW status, charging/battery status of CG 2000/ZB-S devices. Items with faults will be marked with *, and up to 4 types of status/faults can be displayed.

<Setup CG Controller>menu: Controller local configuration, core functions include language selection (German/English), time and date settings (supports daylight saving time/standard time switching), FT/DT test cycle settings (FT defaults to 7 days, DT defaults to 12 months), relay programmable settings (default linkage deep discharge protection/total fault), password management (6-digit password, can be activated/disabled), network mode (default main mode, supports observer mode).

Test cycle safety function: The set FT/DT time will be synchronized to all devices, and the devices will automatically save the test time plus 1 hour. If the controller fails, the device will automatically execute the test according to this backup time.

<Setup device>menu: Device management, ① Find devices autoim: Automatically find devices (will delete existing device records); ② Adding/deleting manually: To manually add or delete CG 2000/ZB-S devices, a unique device address and NID must be entered; ③ Synchronising clocks: Manually/automatically synchronize all device clocks, triggering automatic synchronization in 8 scenarios (such as automatically checking devices, changing controller time, starting tests, etc.).

Memory Card "menu: SD card management core, supports log viewing/deletion, controller configuration saving/loading, SD card reading/writing of device configuration/text, full device data backup to SD card. When there is no SD card, the logs are stored in the controller EPROM, and the logs stored on the SD card can view detailed fault information.

SD card management and PC software linkage

The SD card serves as the core storage and configuration transmission medium for the controller, and supports batch configuration in conjunction with PC software. The core content includes:

SD card storage files: Fixed naming format, core files include configcg.dat (controller configuration), logbook.dat (running logs), as well as device configuration files (CG 2000: configxx.dat; ZB-S: zbscfgxx. dat), device text files (CG 2000: textexx.dat; ZB-S: zbstxtxx. dat), where xx is the device address (01-32).

SD card core operation: ① Save/load controller configuration; ② Read/write configuration/text of a single device; ③ Batch backup of all device data (configuration+text) to SD card; ④ View/delete logs, logs cannot be recovered after deletion.

PC software linkage: The PC side generates controller/device configuration files, stores them on the SD card, and inserts them into the controller. The controller automatically reads the new configuration and completes device search. It can batch transfer the configuration/text to the marked devices to be updated, and supports cancellation/termination of the transfer process.

Fault handling and logging

Fault handling: Faults are displayed by priority on the LCD, and the total number of faults can be entered into the "Info device" menu to view the specific fault type; Relays can be linked to fault alarms, and the triggering time increases with the number of controlled devices (due to the need to complete a round of status polling).

Log recording: The system automatically records all running, testing, and fault events, which are stored on the SD card by default or in EPROM when there is no SD card; The log can be viewed for detailed information (including time, device, and fault type) through LCD, or exported to PC through SD card. Deleting the log is an irreversible operation.