Honeywell XL 800 User Manual

XL 800 Series

FOR SMOKE CONTROL

HONEYWELL EXCEL 5000 OPEN SYSTEM

CONTENTS
General ...............................................................................	3
Before Installation .............................................................	3
Installation .........................................................................	3
Wiring .................................................................................	4
XL800 Series Power Consumption ................................	5
I/O Modules ...................................................................	5
Description of the XCL8010AU Controller Module .........	7
Overview........................................................................	7
Interfaces and Bus Connections ..................................	10
Technical Data.............................................................	10
System Data...........................................................	10
Operational Environment .......................................	10
Smoke Control Configuration.......................................	10
Data File Set-Up ..........................................................	11
Panel Reset .................................................................	11
Typical Power Limited Circuit for XL800 ......................	11
Connecting Single Bus Controller Systems .................	11
XCL8010AU, I/O Modules on Single Rail...............	12
Multiple Rails in Single Cabinet..............................	12
LonWorks Bus I/O Modules in Separate Rooms ....	12
How to Connect Panel Bus and LONWORKS Bus Mixed
Controller Systems ......................................................	12
Connecting I/O Modules.........................................	12
Connecting I/O Modules to the XCL8010AU..........	12
Setting Address of Panel Bus I/O Modules..................	13
Setting the I/O Bus Switch ...........................................	14
LONWORKS Bus Topologies..........................................	14
C-Bus Topologies ........................................................	14
Mounting/Dismounting Modules....................................	14
Mounting/Dismounting Controller/Sockets ...................	15
Mounting Sockets...................................................	15
Connecting Sockets ...............................................	15
Dismounting Sockets .............................................	16
Mounting/Dismounting Electronic Modules ..................	16
Mounting Electronic Modules .................................	16
Dismounting Electronic Modules ............................	17
Connecting via C-Bus ..................................................	17
Connecting to the Controller...................................	17
Setting the C-Bus Termination Switch....................	17
Shielding ................................................................	17

INSTALLATION AND COMMISSIONING INSTRUCTIONS

Connecting HMIs or Laptops........................................	17
Connecting the XI582 Operator Interface ...............	17
Connecting Laptops (XL-Online/CARE) .................	18
XCL8010AU Terminals...........................................	18
Features.......................................................................	18
LONWORKS Interface and Terminals .......................	18
LONWORKS Service LED and Button.......................	18
C-Bus Tx LED and Rx LED ....................................	19
Reset Button...........................................................	19
HMI Interface..........................................................	19
Alarm and Power LEDs ..........................................	20
Watchdog Status ....................................................	20
Modem Interface.....................................................	20
I/O Bus Switch S2...................................................	20
C-Bus Termination Switch S1.................................	21
Memory ..................................................................	21
Description of the I/O Modules .......................................	21
Common Features .......................................................	21
Analog Input Modules ..................................................	22
Types of Analog Input Modules ..............................	22
Features .................................................................	22
Terminals................................................................	22
XFL821AU Connection Examples ..........................	23
Analog Output Modules................................................	24
Types of Analog Output Modules ...........................	24
Features .................................................................	24
Terminals................................................................	24
Technical Data........................................................	24
Modules with Manual Overrides .............................	25
XFL822AU Connection Example ............................	25
Synchronization Behavior of Analog Output Module
Configured as Floating Output................................	25
Binary Input Modules ...................................................	26
Types of Binary Input Modules ...............................	26
Features .................................................................	26
Terminals................................................................	26
Technical Data........................................................	26
Status LEDs............................................................	27
XF823AU Connection Examples ............................	27
Relay Output Modules..................................................	28
Types of Relay Output Modules .............................	28
Features .................................................................	28
Terminals................................................................	28
Permissible Loads ..................................................	29
Status LEDs with Manual Overrides .......................	29
Connection Examples.............................................	30

Copyright © 2008 Honeywell GmbH All Rights Reserved

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General	Excel 800
Troubleshooting...............................................................	31
Testing Wiring Connections..........................................	31
Troubleshooting on the XCL8010AU Controller............	31
Power LED (green) .................................................	31
Alarm LED (red) ......................................................	32
LONWORKS Service LED..........................................	32
C-Bus Tx and Rx LEDs...........................................	33
HMI Tx and Rx LEDs ..............................................	33
I/O Modules Troubleshooting........................................	34
Power LED of I/O Modules .....................................	34
Service LED of I/O Modules....................................	35

Trademark Information

Echelon, LON, LONMARK, LONTALK, LONWORKS, Neuron, are trademarks of Echelon Corporation registered in the United States and other countries.

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Excel 800

WARNING

This equipment generates, uses, and can radiate radio frequency energy, and if not installed and used in accordance with the instructions manual, may cause interference to radio communications. It has been tested and found to comply with the limits for a Class A computing device pursuant to Subpart J of Part 15 of FCC Rules, which are designed to provide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area is likely to cause interference, in which case the user, at his own expense, will be required to take whatever measures may be required to correct the interference. Any unauthorized modification of this equipment may result in the revocation of the owner’s authority to continue its operation.

General

The XL800 Series is designed to provide heating, ventilating and air-conditioning control. They can operate either standalone, or networked to Honeywell central workstations such as EBI. These controllers can also be used for smoke control system monitoring and control, for monitor and control of fire (UL864), and general purpose signaling (UL2017). In UL 2017 applications, the product can be used as a type NM (Non-Monitored) system. It is also approved for UL916 (Energy Management Equipment.)

The XL800 Series can be used for smoke control applications when used in conjunction with a UL listed fire alarm control panel (FACP) and UL listed fire fighters’ smoke control station (FSCS).

Before Installation

1.Unpack door and remove the XL800 from carton. Check equipment and report any damage to a Honeywell representative.

2.Verify cabinet is installed correctly.

3.Securely mount the XL800 to a rigid structural surface using at least four sets of 1/4 in. (6 mm) mounting hardware (supplied locally).

NOTE: Anchoring materials must be suitable for the mounting surface (wood, concrete, steel). Mounting must comply with all local codes.

4.Obtain correct number and type of sheet metal screws for subpanel. Installation of a full-size subpanel requires six no. 10 x ½-inch (13 mm) sheet metal screws (not supplied). Installation of a smaller subpanel requires four no. 10 x ½-inch (13 mm) sheet metal screws (not supplied).

5.Obtain 14505159-001 Tamper Switch per job requirements. Installation of Tamper Switch is optional.

Installation

Mount controller subpanel in cabinet so all labeling is visible. Secure full-size subpanel in place with six no. 10 x ½-inch (13 mm) sheet metal screws (not supplied). Secure smaller subpanel with four no. 10 x ½-inch (13 mm) sheet metal screws (not supplied).

NOTE: Subpanel must mount flat and should not bulge or recess anywhere.

FULL-SIZE

CABINET

SIX NO. 10 x ½-INCH (13 mm)

SHEET METAL SCREWS

Fig. 1. Mounting controller subpanel in cabinet (full-size subpanel cabinet shown)

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Wiring

Excel 800

Wiring

All wiring to the XL800 controller is unsupervised, except as noted.

All circuits are power limited, except for AC power circuits, relay contacts and other circuits as noted.

All field wiring terminals accept 24 AWG to 14 AWG (0.25 mm2 to 2 mm2) conductors except as noted.

All wiring must conform to local codes, ordinances, and regulations. Refer to job drawings for details.

Verify that the voltage difference between any conductor and earth ground does NOT exceed 150 Vac.

1.Connect input/output device wiring, C-Bus transmission wiring (minimum 18 gage [0.8012 sq mm]), LON Bus transmission wiring, and 14507063 Power Cable to Controller per job drawings. Fig. 2 and Fig. 3 show typical controller wiring. Four Power Module models are available (see Table 2).

2.Connect line voltage to Terminals H and N of the 14507287 Power Module. Connect a good earth ground to Terminal G of the Power Module. Fig. 5 through Fig. 7 show typical power wiring.

3.For Power Modules -001 through -007, leave power to Power Supply and Controller OFF. Connect 14507063 Power Cable from Controller to Power Module.

WARNING

Risk of electric shock or equipment damage!

►Subpanel and Controller power must remain OFF until Controller is checked.

4.Install optional Tamper Switch on cabinet per instructions in the cabinet installation instructions. Wire Tamper Switch per job drawings.

5.Mount cabinet door.

CAUTION

Risk of electric equipment damage! Excessive static can burn out equipment.

►Observe proper anti-static material handling practices when installing or servicing PC parts and related components.

►Observe proper equipment and body grounding practices.

►Discharge static electricity from your body before handling parts.

		Table 1. Connector terminal specifications
connector terminal	pin	signal type	input /	voltage	max.	max. current
			output	type	voltage

analog input	AI	input	SIGNAL	±12 V	±20 mA
digital input	DI	input	SIGNAL	±10 V	±20 mA
analog output	AO	output(1	SIGNAL	±10 V	±20 mA
digital output	DO	output(2	AC/DC	±24 VAC/DC	±50 mA
totalizer output	TI	input	SIGNAL	±12 V	±12 mA
signal ground	GND	--	--	--	--
J1 RS-485 (C-BUS) (3 1	+A	input / output	SIGNAL	±5 V	1 mA / 180 mA
2	-A	input / output	SIGNAL	±5 V	1 mA / 180 mA
3S	Shield A	--	--	--	--

(1 special application; (2 regulated; (3 supervised

max.	max. line
frequency	impedance
9600 baud	8K ohms

--15K ohms

9600 baud 8K ohms

--10K ohms

100 Hz

----

9600 baud	100 ohms
9600 baud	100 ohms

----

Table 2. Power module models

	model		transformer max. input				(48 VA) controller		accessory output				convenience outlet
			Vac	current draw	Hz		VAC output
14507287-001		120		0.5 A	60	24							120 Vac, 10A
14507287-002		120		1.7 A	60	24		24	Vac, 100	VA, 24	Vac, 40 VA		120 Vac, 10A
14507287-003		120		1.7 A	60	24		24	Vac, 100	VA, 24	Vdc, 600 mA		120 Vac, 10A
14507287-007		120		120 A	60	24		--				--

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Excel 800		Wiring
XL800 Series Power Consumption		I/O Modules

When selecting the appropriate power supply, the power consumption of the XL800 modules must be taken into account.

Table 3. XL800 power consumption

	max. power consumption
model	24 Vac, 60 Hz	24 Vdc
XCL8010AU with	690 mA	640 mA
watchdog load
XCL8010AU without	190 mA	140 mA
watchdog load
XF821AU, XFL821AU	130 mA	80 mA
XF822AU, XFR822AU,	160 mA	90 mA
XFL822AU, XFLR822AU
XF823AU, XFL823AU	180 mA	130 mA
XF824AU, XFR824AU,	140 mA	90 mA
XFL824AU, XFLR824AU
XFR825AU	140 mA	90 mA

Variants of I/O Modules

There are two variants of I/O modules:

•Panel Bus I/O modules with communication via Panel Bus (light-gray housings)

Modules are automatically commissioned (with firmware download) by the XCL8010AU

•LONWORKS Bus I/O modules (dark-gray housings) with

communication via LONWORKS (FTT10-A, link power compatible) for easy integration and use with 3rd-party controllers

Terminal Sockets

I/O modules are mounted on the appropriate terminal sockets. Panel Bus I/O modules and LONWORKS Bus I/O modules use the same terminal sockets.

Color Coding

To distinguish modules and components, the following color coding is used:

Table 4. Color coding of Excel 800 Modules

	color		part
	red		All of the user-accessible adjustable
			mechanical parts (i.e., bridge connectors and
			locking mechanism) and operating controls
			(manual overrides, etc.)
	light-gray		Panel Bus I/O modules
	dark-gray		LONWORKS Bus I/O modules

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Wiring Excel 800

ANALOG	ANALOG	BINARY	RELAY	FLOATING
INPUT	OUTPUT	INPUT	OUTPUT	OUTPUT

LonWorks
			XFLR822AU					XFLR824AU
BUS
MODULES
	XFL821AU		XFL822AU			XFL823AU		XFL824AU

PANEL

XFR822AU

XFR824AU

XFR825AU

BUS

MODULES

XF821AU

XF822AU

XF823AU

XF824AU

XCL8010AU	XS821-22			XS823		XS824-25

CONTROLLER MODULE		LonWorks or Panel Bus
	Fig. 2. Overview of I/O modules and terminal sockets

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Excel 800

Description of the XCL8010AU Controller Module

Description of the XCL8010AU Controller Module

Overview

PC or HMI

EXCELON

I/O MODULES

			NO CONNECTION
	LonWorks BUS		C-BUS
	Fig. 3. Connections to the XCL8010AU Controller
		Legend
		1	Power supply for I/O modules
		2	I/O Bus communication terminals
		3	LONWORKS interface
		4	LONWORKS service button
		5	LONWORKS service LED
		6	C-Bus Tx LED
		7	C-Bus Rx LED
		8	Reset button
		9	HMI interface (for field use, only)
		10	Alarm LED
		11	Power LED
		12	Power supply terminals
		13	Alarm/watchdog outputs
		14	NO CONNECTION
	Fig. 4. XCL8010AU Controller Module front details	15	S2 I/O Bus switch
		16	S1 C-Bus termination switch
		17	C-Bus terminals
		18	LONWORKS terminals

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Description of the XCL8010AU Controller Module

Excel 800

24 VAC CONTROLLER POWER SWITCH

MAIN LINE VOLTAGE 120 VAC, 60 HZ TERMINAL “G“ MUST BE

CONNECTED TO A GOOD EARTH GROUND.

		14507063-002 POWER CABLE
	(incl. with 14507287 power modules
	14507287-001 through -003, only.)
CONNECTOR TO			BRN
			GRN
XL800 CONTROLLER
			BLK
J5
		CONNECTORS ARE KEYED TO
		PREVENT MISALIGNMENT.
		CONVENIENCE OUTLET
		(UNFILTERED, UNSWITCHED)
			-001 = 120 VAC, 10 AMP

120 VAC, 60 HZ

LINE INPUT

2 AMP

FUSE F1 (2 AMPS) PART NUMBERS ARE AS FOLLOWS:

CONTROLLER

–HONEYWELL PART NO. 14000485-007

F1

*

POWER

(AVAILABLE FROM HONEYWELL BRANCH LOCATIONS, ONLY)

–BUSSMAN PART NO. AGC-2

H

ON

–LITTLEFUSE PART NO. 312002

N

OFF

G

CONTROLLER

SUPPLY

24VAC

48VA ~

MUST BE WIRED

G

TO EARTH GROUND

“G“ MUST BE

UNSWITCHED

WIRED TO EARTH GROUND

UNFILTERED

120VAC

*14507287-001 POWER TERMINALS LABELED H-N-G.

Fig. 5. Typical 14507287-001 Power Module wiring

24 VAC CONTROLLER POWER SWITCH

MAIN LINE VOLTAGE 120 VAC, 60 HZ TERMINAL “G“ MUST BE

CONNECTED TO A GOOD EARTH GROUND.

		14507063-002 POWER CABLE
	(incl. with 14507287 power modules
	14507287-001 through -003, only.)
CONNECTOR TO			BRN
			GRN
XL800 CONTROLLER
			BLK
J5
		CONNECTORS ARE KEYED TO
		PREVENT MISALIGNMENT.
		CONVENIENCE OUTLET
		(UNFILTERED, UNSWITCHED)
			-002 AND -003 = 10 AMP

120 VAC, 60 HZ LINE INPUT

		CONTROLLER		2 AMP			5 AMP
				F1			F2
	*	POWER
	H	ON				ON
	N	OFF				OFF			~
	G						2 AMP
		CONTROLLER					F3
		SUPPLY	MUST BE WIRED
		24VAC	TO EARTH GROUND

48VA ~

G

120 VAC, 60 HZ LINE INPUT

24VAC ACCESSORY POWER -002 AND -003 MODELS (4 AMP MAX.)

	24 VAC ACCESSORY POWER
“G“ MUST BE	-002 MODEL, ONLY. 2 AMP MAX.
WIRED TO EARTH GROUND
	FOR 14507287-003 (24VDC)	BRN	GRY	BRN	GRY
	FOR 14507287-002 (24VAC)	RED	BRN	GRY	GRY
	UNSWITCHED
	UNFILTERED 120 VAC

* 14507287-001 POWER TERMINALS LABELED H-N-G.

POWER MODULE	FUSE NO.	FUSE RATING	HONEYWELL PART NO.	BUSSMAN PART NO.	LITTLEFUSE PART NO.
14507287-001 THROUGH -003	F1	2 AMPS	14000485-007	AGC-2	312002
14507287-002 AND -003	F2	5 AMPS	14507374-001	GMA 5AMP	235005
14507287-002 AND -003	F3	2 AMPS	14000485-007	AGC-2	312002

Fig. 6. Typical 14507287-002, -003 Power Module wiring

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Excel 800

Description of the XCL8010AU Controller Module

CONTROLLER TRANSFORMER

GRN

CONTROLLER

G

70

BRN

SUPPLY 24 VAC

~

71

48 VA

BLK

72

3

4

BLK

H

WHT

N

GRN

G

MAIN LINE (120 VAC, 60 Hz)

TERMINAL “G” MUST BE

CONNECTED TO A GOOD

EARTH GROUND.

24 V 50 VA

14507351-001 429P156A E1A 1052 XXXX

COM 120 V

1 2

1

1

1 MECHANICALLY SECURED TO SUBPANEL WITH MOUNTING SCREW

Fig. 7. Typical 14507287-007 Power Module wiring

I/O Module Overview

Table 5. Overview of I/O modules

Panel Bus	LONWORKS	description	inputs	outputs	manual controls	LEDs 1)
module	Bus module
XF821AU	XFL821AU	Analog Input Module	8	–	–	–
XF822AU	XFL822AU	Analog Output Module	–	8	–	8 status LEDs
XFR822AU	XFLR822AU	Analog Output Module	–	8	8 manual overrides	8 status LEDs
XF823AU	XFL823AU	Binary Input Module	12	–	–	12 status LEDs
XF824AU	XFL824AU	Relay Output Module	–	6 2)	–	6 status LEDs
XFR824AU	XFLR824AU	Relay Output Module	–	6 2)	6 manual overrides	6 status LEDs
XFR825AU	–	Floating Output Module	–	3	3 manual overrides	3 pairs of status LEDs

1)In addition to the power LED and service LED

2)Changeover outputs

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Description of the XCL8010AU Controller Module

Excel 800

Corresponding Terminal Sockets

Table 6. I/O modules and corresponding terminal sockets

	I/O module			socket			scope of delivery
	XF821AU,						1 terminal socket,
	XFL821AU						1 bridge connector
							1 swivel label holder
	XF822AU,			XS821-22
	XFL822AU,
	XFLR822AU,
	XFR822AU
	XF823AU,						1 terminal socket,
				XS823			1 bridge connector
	XFL823AU
							1 swivel label holder
	XF824AU,						1 terminal socket,
	XFL824AU,						1 bridge connector
	XFLR824AU,			XS824-25			1 swivel label holder
	XFR824AU						1 long cross connector
	XFR825AU

Interfaces and Bus Connections

The Excel 800 System can be connected to the following devices and systems:

Panel Bus

•For communication with up to 16 Panel Bus I/O modules

•Polarity-insensitive

LonWorks Bus

•For communication with other LONWORKS Bus devices within the building

•FTT10, link power compatible

•Polarity-insensitive

C-Bus

• For communication with other controllers

HMI

•For connecting an operator interface, e.g., XI582 or a laptop, e.g., for CARE

Modem

• NO CONNECTION

Technical Data

System Data

Table 7. System data

Operating voltage	24 VAC/DC, 60 Hz
	Max. 3.57 A
Power consumption
	(1 XCL8010AU Controller
	+ 16 I/O modules)

Operational Environment

Table 8. Operational environment

ambient operating	0	─ 49 °C (32 ─ 122 °F)
temperature
ambient operating	5	─ 93 % rel. humidity
humidity	(non-condensing)
ambient storage	–20 ─ +70 °C (–4 ─ +158 °F)
temperature
ambient storage	5	─ 95 % rel. humidity
humidity	(non-condensing)

Smoke Control Configuration

SMOKE CONTROL CONFIGURATION

XL800

9

AO

SUPPLY

4

11

FAN

UL-LISTED

8

AIRFLOW SENSOR

FIRE ALARM

AO

EXHAUST

5

CONTROL UNIT

12

FAN

FIREFIGHTERS’

2

AO

DAMPER 3

SMOKE CONTROL

PANEL (FSCS)

VERIFICATION

14505068

AUDIBLE

1

ANNUNCIATOR

10

6

7

STATUS CONTROL

Fig. 8. Typical smoke control configuration

NOTES:

1Locate and configure per NFPA 92A, Section 3-4.3.4. UL-listed annunciator / FSCS panel switches have a minimum rating of 24 V, 1/10 Amp, and lamps / LEDs have a rating of 24 V, limited to 50 mA.

2Locate so as to minimize control wiring and piping. Avoid running wires or piping through areas that have a high fire risk.

3Locate per UL 555S.

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Excel 800

Description of the XCL8010AU Controller Module

4Locate separate from and below all building exhaust fans and upstream of any prevailing winds.

5Exhaust to outside of building.

6Locate airflow differential switch.

7Locate UL-listed damper pressure / position indicator per damper installation instructions.

8Smoke control must be initiated by a listed fire alarm control unit or in zone automatic alarm devices and not devices located outside of the smoke control zone. Interconnecting wiring must be within 20 ft. (6 meters) and in conduit.

9Refer to NFPA 92A.

10Verify that the AC voltage source connected to the inside of the main line voltage terminal block is from a UL-1481 listed uninterruptible power supply. The main line voltage terminal block maximum current draw is 0.5 A. For 220/240 VAC (60 Hz) applications, verify that no potential between any conductor and the earth ground exceeds 150 VAC.

11All external LONWORKS bus field wiring must be limited to 4000 ft. (1200 meters) and be terminated to 14506944-001 transient protector (35 V, 290 mA max.) except C-Bus field wiring communicating at 1 MHZ, which uses 14502412-014 transient protector (19 V, 500 mA).

12Panel Bus wiring must be in the same enclosure or less than 20 ft. to adjacent enclosure. No protection is required.

Data File Set-Up

Generate the engineering data file for the XL800 Series Controllers. This data file has a mix of hardware points for the necessary inputs and outputs to control fans, dampers, and other equipment. In addition to the inputs and outputs, a custom control program is written to control the outputs per the sequence. The XL800 controllers can reset the program once the data from the operator interface indicates a normal condition for the dedicated smoke control equipment. Wire conditions must be programmed to provide annunciation of trouble conditions.

Also required for a dedicated application for the XL800, is a weekly time program to test control points, fans, and dampers by exercising the equipment and verifying feedback automatically during low building activity periods.

Panel Reset

When in Smoke Control Mode, panel reset is accomplished by resetting the initiating panel contact circuit or by the separate initiating/reset switch on the FSCS panel.

CAUTION

Risk of electric equipment damage!

►Failure to use listed/approved replacement parts can damage product, degrade operation and result in loss of safety function.

►This product must be installed and operated within its environmental, mechanical, and electrical specifications as contained in this document.

►When servicing, use only listed/approved replacement parts ordered directly from the manufacturer.

Typical Power Limited Circuit for XL800

POWER

POWER

LIMITED

LIMITED

NON-POWER

2

CPU

ANALOG INPUT

ANALOG OUTPUT

DIGITAL INPUT

DIGITAL OUTPUT

LIMITED

MODULE

MODULE

MODULE

MODULE

POWER LIMITED

24VAC

CONTROL

24VAC

ACCESSORY

NON-POWER

24VAC

LIMITED

2

2

3

1

1

NON-POWER

LIMITED

NON-POWER

LIMITED

Fig. 9. Typical power-limited circuit for XL800

114507287-001 through -003 power module accessory 24 VAC output (rated 2A) must be wired in accordance with NFPA 70, Article 725 when routed within the cabinet or adjacent cabinets and also for external field wiring.

214507287-001, -002, -003, and -007 control power module 24 VAC output is inherently power-limited. Thus, all sourced power from the XL800 controller is power-limited. All field wiring from these controllers meet NFPA 70, Article 725 power limited Class II requirements.

3If a separate auxiliary power-limited 24 VAC power source is required, use a control power module (14507287-001 or -007 control supply).

4Devices must be installed in areas as shown. All cable must be routed as shown. All internal power-limited wiring must be separated by ¼ inch (6 mm) or barrier from non-power-limited wire. Excess wiring must be cut, trimmed, and dressed properly to ensure that proper clearances are maintained.

Connecting Single Bus Controller Systems

This section describes how to connect a controller system which uses Panel Bus I/O modules, only or LONWORKS Bus I/O modules, only.

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