Eaton CEAG CG Controller Comprehensive Guide

Eaton CEAG CG Controller for CG 2000/ZB-S: Intelligent Control Core for Emergency Lighting System

Introduction

In modern buildings and industrial facilities, emergency lighting systems are key equipment for ensuring the safe evacuation of personnel. Eaton, as a global leader in power management, has launched the CG Controller controller under its CEAG brand specifically designed for CG 2000 and ZB-S emergency lighting systems, providing centralized monitoring, testing, fault recording, and configuration management functions. This article is based on the official operating manual (document number: 30080001458), which comprehensively analyzes the functional characteristics, installation requirements, operating interface, menu system, and maintenance methods of CG Controller, providing professional technical references for electrical engineers and system integrators.

Product Overview and Technical Specifications

1.1 Applicable System

CG Controller is dedicated to monitoring and controlling the following CEAG safety lighting systems:

CG 2000 System: Central Power Supply Emergency Lighting System with Star Topology

ZB-S System: Distributed Emergency Lighting System Using Bus Technology

The controller can manage up to 32 systems of the same type simultaneously, communicate with each system through the LON FTT 10A interface, obtain real-time status information, and execute control instructions.

1.2 Technical Parameters

Parameter specifications

Power supply voltage 230 V AC ± 10% or 24 V DC

Power consumption 230V: 80 mA max; 24V: 450 mA max

Alarm contact 1 set of passive conversion contacts, 24V/0.5 A, freely programmable

Communication interface LON FTT 10A (connected to CG 2000/ZB-S)

Display backlit LCD, 4 lines x 20 characters, alphanumeric

Protection level IP65 (compliant with EN 60527)

Environmental temperature -5 ° C...+40 ° C

Relative humidity 0-95%, no condensation

The maximum size of the wiring terminal is 2.5 mm ²

Weight approximately 1.8 kg

Dimensions 184 x 240 x 112 mm

1.3 Compliance with standards

VDE 0108/10.89 (Standard for Emergency Lighting Systems)

DIN/VDE 0805/11.93 (Information Technology Equipment Security)

IEC 950 (Information Technology Equipment Security)

Development, manufacturing, and testing comply with DIN EN ISO 9001

Compliant with EU EMC Directive 89/336/EEC and Low Voltage Directive 73/23/EEC (as revised by 93/68/EEC), with CE marking

Safety regulations and operational responsibilities

2.1 Safety Warning

Unauthorized or unprofessional operation of equipment may result in the failure of main or emergency lighting, causing serious harm to personnel or equipment.

Before carrying out any operation on the emergency lighting system, it is necessary to ensure that the system has been powered off and to pay attention to the isolation between normal power supply and emergency power supply.

It is necessary to comply with the national safety regulations and accident prevention requirements for the installation and operation of electrical equipment.

2.2 Operator Responsibilities

The operator of the emergency lighting system is responsible for:

Organize and supervise all related work

Written regulations on job responsibilities, recording methods, responsible persons, and authorities

Develop and implement safety measures such as backup lighting, power isolation, lockout and tagout, safety signage, etc

Ensure regular inspection and testing of statutory requirements (functional testing, duration testing)

Record and archive the test results for regulatory review

2.3 Compliance Tips

The planning and programming of the system must be carried out by engineering personnel with professional knowledge

All modifications and security checks should be made by contacting the local CEAG office or authorized experts

Using CG-S lamps/ballasts not provided by CEAG may not guarantee full functionality

Installation and electrical connection

3.1 Mechanical Installation

The controller can be wall mounted (drilled according to Figure 1) or installed on a 35 mm DIN rail.

The fixing screws only need to be tightened by hand.

The installation location should avoid vibration, moisture, and corrosive gases, and the ambient temperature should be between -5 ° C and+40 ° C.

3.2 Electrical Connections

Power connection (see Figure 2):

230 V AC wiring: L (live wire), N (neutral wire), PE (ground wire)

24V DC wiring:+24V, GND

Maximum terminal capacity of 2.5 mm ²

Alarm contact (terminals 1-2-3):

Passive conversion contacts, programmable to be assigned to various events (such as total faults, battery failures, etc.)

Load capacity: 24V/0.5 A

Bus connection (see Figure 3):

Connect the bus cable from CG 2000 or ZB-S system to terminal A (2) B (2)

Each input provides 4 terminals for easy star or handle wiring

3.3 Initial Startup Settings

After power on, the LCD prompts to enter the current time and date, and confirm using the menu key or ← key.

To ensure accurate logging, all system clocks need to be synchronized:

Menu → Device Settings → Synchronize Clock

Register one or more emergency lighting systems:

Menu → Device Settings → Automatic Device Search

User interface and operation

4.1 Keyboard Definition

Key function

Switch the menu from the main screen to the main menu; Return to the previous level in the submenu and accept changes

Confirm the selection; Open the menu item; Exit input and accept

↑/↓ Move the cursor up and down

←/→ Move the cursor left/right; Reduce/increase value; Activate/Disable Options

4.2 LCD Main Screen

Line display content

1 software version (such as CG 2000/ZB-S)

2 status display (such as "running", "functional testing in progress")

3 Fault Display (such as "Communication Fault Device 03")

4 time and date (e.g. 13:29:17 26.10.2002)

If there is no malfunction, the third line will be empty.

If there is no button operation for more than 3 minutes, the system will automatically return to the main screen.

Press any key to turn on the backlight, which will turn off after about 3 minutes.

Detailed explanation of menu system

The menu structure of CG Controller is clear, mainly divided into six modules: testing, blocking/resetting, device information, setting controller, setting device, storage card, etc.

5.1 Test menu

Functional testing (FT):

Single device: Start functional testing after selecting the device (usually for a short period of time)

All devices: Start functional testing for all registered systems

Duration Test (DT):

Single or all devices start duration test (until the battery is depleted or reaches the set time)

Can be cancelled in advance during the testing process

5.2 Block/Reset Menu

Block: Manually prevent certain devices from automatically testing or emergency starting

Manual reset: When the system enters emergency mode due to a main power failure, if manual recovery is required (such as in a cinema dimming scene), perform a manual reset in this menu

5.3 Equipment Information Menu

After selecting a device, you can view:

Circuit status (priority list of CG2000 or ZB-S line status)

Lamp status (whether each circuit lamp is normal)

DLS/TLS/3PhW status (dimming module, three-phase monitoring module)

Charging/battery status (battery voltage, charger status)

Faults are displayed by priority. If there are multiple faults, press the confirm button to scroll through them.

5.4 Setting Controller Menu

Language selection: Supports multiple languages (default English)

Time/Date: Can be manually set, automatically adjusted by pressing the 7 key (summer time) or the 9 key (standard time)

Next FT Functional Test: Set a unified functional test date and time for all devices

Next DT: Set a unified duration test date and time

Relay settings: Select which states or faults trigger the alarm relay (such as total fault, battery fault, etc.)

Serial Number: Display the hardware serial number of the controller (cannot be changed)

Customer service information: Display the software versions of the control unit, memory card, and LON card

Password: Password protection can be enabled to prevent unauthorized menu access (if you forget your password, you can contact the manufacturer for a universal password)

NID reception: waiting for service request message (for remote diagnosis)

Network main station: default to main station mode; If parallel with other monitoring systems, it needs to be set to observer mode (some functions are not available at this time)

5.5 Set Device Menu

Automatic device search: Scan CG2000 or ZB-S systems on the bus and register (note: this operation will delete the existing device list)

If the device cannot be found, check if the device address is>0 and unique, or if the LonWorks domain length is 0

Manual addition/deletion: Enter the system number and NID (Node ID) to manually add devices

Synchronize clock: Manually or automatically synchronize all device clocks with the controller

5.6 Memory Card Menu

Use standard Secure Digital (SD) cards for data backup and recovery:

Display logs: View device events recorded by the controller (such as test results, fault records)

Delete log: Clear log (unrecoverable)

All devices → SD: Backup controller configuration, all device configurations, and text (lamp name, circuit name) to SD card

Controller configuration ↔  SD: Backup or restore the settings of the controller itself

Device Configuration ↔  SD: Backup or restore the configuration of a single device

text ↔  SD: Backup or restore user-defined text in the device (such as lamp position description)

LED indicator light and fault diagnosis

6.1 Front panel LED

Meaning of LED color

Green operation preparation, all systems are running normally

At least one system is undergoing functional or duration testing in yellow test mode

At least one system reports a fault in red (specific fault information needs to be viewed)

6.2 Fault priority and total faults

Faults are arranged in descending order of priority (such as communication faults, main power supply faults, battery faults, etc.)

When multiple faults exist simultaneously, the LCD displays the highest priority fault and shows an "*" at the end of the line to indicate a total fault

Press the confirm button to view all fault lists

Common fault examples:

Communication failure device XX: Lost contact with a certain device (possibly due to bus interruption or device offline)

Main power failure: The main power supply of a certain device loses power

Battery failure: abnormal battery voltage, battery interruption, or insufficient capacity

Charging/insulation failure: Charging module failure or insulation degradation

Lamp malfunction: Lamp failure in a certain circuit (detected through functional testing)

Insufficient minimum duration: battery aging leads to discharge time not meeting the standard

SD card data management

7.1 File Structure

After inserting the SD card, the controller will automatically create the following files:

Configcg.dat: Controller configuration file

Logbook.dat: Controller log (binary format)

For CG2000 system: configXX.dat (XX is 01-32) texteXX.dat

For ZB-S system: zbscfgXX.dat, zbstxtXX.dat

7.2 Generating Configuration from PC Software

By using PC software such as CGVision, the system configuration can be pre edited, configcg.dat can be generated, and the SD card can be inserted. After inserting the controller, the system detects a new configuration (address 0x060 marked as 0x01) and automatically prompts and loads it.

The loading process includes: reading new configuration → automatically finding devices → saving the current configuration back to SD (marked as 0xFF)

If there is a change in the device list, the PC software will also generate configXX.dat and texteXX.dat, and the controller will automatically download the updates to the corresponding devices.

7.3 Data Flow Diagram

Equipment (CG2000/ZB-S) ↔  CG Controller ↔  SD card ↔  PC software

All system data can be backed up offline through SD card for easy archiving or batch configuration.

Maintenance and regular testing

8.1 Regulatory requirements

According to national electrical regulations (such as VDE 0108 in Germany), emergency lighting systems must undergo regular functional testing and duration testing, and records must be kept. CG Controller automatically records each test result, and the operator can:

Manually start the test from the menu

Set automatic testing plan (next FT/DT)

Check the logs to confirm if the test passed

Export logs to PC for archiving

8.2 Safety Features

Next test time+1-hour safety margin: If the controller fails to start the test at the scheduled time due to a malfunction, the device will automatically start the test one hour later to ensure compliance.

Manual reset: suitable for places that require manual confirmation of recovery (such as theaters), to prevent automatic switching back to normal mode after emergency and affecting performances.