Honeywell EXCEL 100C INSTALLATION INSTRUCTIONS

HONEYWELL EXCEL 5000 OPEN SYSTEM

Excel 100C

CONTROLLERS

INSTALLATION INSTRUCTIONS

Copyright © 2009 Honeywell Inc. • All Rights Reserved EN1R-0144GE51 R1109

EXCEL 100C INSTALLATION INSTRUCTIONS

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EN1R-0144GE51 R1109 2

EXCEL 100C INSTALLATION INSTRUCTIONS

Contents

REVISION OVERVIEW.................................................................................................................................................................. 5

INTRODUCTION............................................................................................................................................................................ 6

General Safety Instructions....................................................................................... 6

Technical Requirements............................................................................................ 6

Auxiliary Devices ...................................................................................................... 6

DEVICE ASSEMBLY AND SYSTEM INSTALLATION................................................................................................................... 7

Assembly of Controller Housing................................................................................ 7

Control Cabinet Installation....................................................................................... 8

Meaning of Control Lamp ......................................................................................... 9

Terminal Assignment Overview for Excel 100C ...................................................... 10

General Remarks about Electrical Connections ......................................................11

Cable Routing ..........................................................................................................11

Shielding of Sensor and Actuator Cables.................................................................11

Shielding of Data Transmitting Cables (System Bus and Operator Interface)......... 12

System Ground....................................................................................................... 12

RFI Suppression ..................................................................................................... 12

Cable Lengths and Cross Sectional Areas.............................................................. 13

Line Power Supply.................................................................................................. 14

Communication....................................................................................................... 14

ELECTRICAL CONNECTION...................................................................................................................................................... 16

Terminal Assignment for Digital Inputs .................................................................... 18

Terminal Assignment for Relay Modules ................................................................. 19

Terminal Assignment for Relays and Actuators....................................................... 21

Connection of Alarm Relays.................................................................................... 22

Normally Open/Normally Closed Attribute............................................................... 22

System Bus (C-Bus) ............................................................................................... 23

Connections to Operating Device ........................................................................... 24

REMOTE COMMUNICATIONS.................................................................................................................................................... 30

Modem or ISDN* Terminal Adapter Connections .................................................... 31

Modem Requirements ............................................................................................ 31

No Set-Up for Standard Modem Behavior............................................................... 31

Automatic Baud Rate Synchronization.................................................................... 32

Auto / Manual Answer Detection............................................................................. 32

Resetting the Modem.............................................................................................. 32

Set-Up for Special Modem Behavior....................................................................... 32

Set-Up for In-house Telephone Systems ................................................................ 32

Set-Up for Limited Communication Speed.............................................................. 33

Troubleshooting ...................................................................................................... 33

BACKLIGHT ................................................................................................................................................................................ 33

DIMENSIONS............................................................................................................................................................................... 34

3 EN1R-0144GE51 R1109

EXCEL 100C INSTALLATION INSTRUCTIONS

U.S. SPECIFICATIONS ................................................................................................................................................................36

Electrical Connection of Sensors.............................................................................36

Transformers ...........................................................................................................38

Cables .....................................................................................................................38

Relays .....................................................................................................................39

Repeaters................................................................................................................39

EUROPEAN SPECIFICATIONS ...................................................................................................................................................40

Electrical Connection of Sensors.............................................................................40

Transformers ...........................................................................................................43

Relays .....................................................................................................................43

Cables .....................................................................................................................43

Repeaters................................................................................................................44

EN1R-0144GE51 R1109 4

EXCEL 100C INSTALLATION INSTRUCTIONS

REVISION OVERVIEW

The changes listed below show the revisions that have been made in comparison to the previous revision.

Page

Changes

26

44

NOTE: The Excel 100 has been developed to meet control requirements worldwide. Some referenced applications /

accessories have been developed to meet specific regional requirements and may not be available or applicable in all
locations.

The adapter cables have been changed.

The ordering information for repeaters with/without housing has been changed.

5 EN1R-0144GE51 R1109

EXCEL 100C INSTALLATION INSTRUCTIONS

INTRODUCTION

General Safety Instructions

Assembly by trained personnel

CAUTION

Assembly must be completed by trained personnel.

Persons who are not trained and authorized to carry out heating and electrical
installation may not carry out assembly work even if this appears possible on the
basis of the instructions.

Install with power off

CAUTION

All assembly work must be completed with power off.

If some parts of the system are nonfunctional or have not yet been received,
assembly may proceed only if power is disconnected from those assemblies. Simply
switching off the unit is insufficient.

Observe regulations

IMPORTANT

The regulations VDE 0800, VDE 0100, U.S. National Electric Code NEC or
others that replace them, absolutely must be observed.

Follow instructions step by step Follow instructions in accordance with the progress of the assembly step by step.

Skip sections only when requested to do so in the text.

Technical Requirements

All devices ready? Assembly can start only if all system components have been installed and are ready

to be operated and the control and measuring sensor cables have been connected
to the control cabinet.

All cables laid? All cables must be clearly marked and laid with appropriate auxiliary accessories

(cable ducts, cable ties).

Delivery complete? The delivery of all system parts must be complete.

Auxiliary Devices

Use documentation

IMPORTANT

Install all devices according to the documentation supplied with the
equipment.

The instructions are designed in such a way that they provide a suggestion for all
foreseeable situations. Should you be confronted with problem during assembly,
please contact your appropriate dealership (see last page). If there is no one to deal
with your query at that particular moment, please contact technical sales support at
the factory.

EN1R-0144GE51 R1109 6

EXCEL 100C INSTALLATION INSTRUCTIONS

DEVICE ASSEMBLY AND SYSTEM INSTALLATION

1

3

5

7

2

4

6

8

Assembly of Controller
Housing

1 Open cover

2 Remove tool

3 Remove screw

4 Loosen housing cover from

base

5 Loosen front right

6 Loosen rear

7 Loosen left

8 Lift housing off base

CB-0700-Mb

7 EN1R-0144GE51 R1109

EXCEL 100C INSTALLATION INSTRUCTIONS

Control Cabinet Installation

XD505

XD508
middle

XD508

beg./end

IMPORTANT

The maximum ambient temperature
for the Excel 100C depends on the
mounting orientation:

Vertical
mounting: max. 122°F (50°C)
Horizontal
mounting: max. 113°F (45°C)

1 Hang onto DIN rails

(see pages 34 and 38 for

mounting dimensions)

2 Secure base

3 Cable holes

4 Snap relay modules into

place (optional)
Electrical connection

(see pages 10, 19 to 21)

5 Set the bus termination

switch on the back of the
housing according to the
system configuration

(see page 14 for details).

6 Fit housing

Make sure it is straight

EN1R-0144GE51 R1109 8

7 Connect operating device

(see pages 24 and up)

IMPORTANT

Set the port selector switch (left to the
sub-D port) according to whether the
front port or the rear terminals should
be active (see page 30 for details).

Front port Rear terminals
active active

b
1
0
7
0

8 Close cover

­B
C

NOTE: Cover cannot be mounted

with front connector plugged.

Meaning of Control Lamp

T

L4 L5 L6 L7

RESET

BUTTON

PORT

SELECTOR

SWITCH

FRONT

SERIAL

POR

EXCEL 100C INSTALLATION INSTRUCTIONS

Table 1. Control Lamps and their meanings

LED color status/meaning

L1 YELLOW Lit: Main voltage is present

L2 GREEN Lit: Program is running

Dark: Program is stopped

L3 RED Lit continuously: ALARM; program is stopped

L4 YELLOW Lit : Controller is transmitting via B-port

L5 YELLOW Lit: Controller is receiving via B-port

L6 YELLOW Lit: Transmission via C-bus to system bus interface

L7 YELLOW Lit: Reception via C-bus from system bus interface

L8, L9, L10, and L11 are for future use

NOTE: L4 to L11 are visible only if the cover plate has been removed.

IMPORTANT

The RESET button reboots the controller’s CPU. All plant­specific data held in the controller will be lost after a reboot.

CB-0603-E1

See section "Setting the Port Selector Switch" on page 30 for details on
setting the port selector switch and serial port.

Before rebooting, it is highly recommended that you save the
current application to the flash EPROM.

9 EN1R-0144GE51 R1109

EXCEL 100C INSTALLATION INSTRUCTIONS

{

{

Terminal Assignment Overview for Excel 100C

ANALOG

INPUTS

DIGITAL

INPUTS

10

11
12
13
14
15
16
17
18
19
20

21
22
23
24
25
26
27
28
29
30

31
32
33
34
35
36

1
2
3
4
5
6
7
8
9

AI 1 xx0101

AI 2 xx0102

AI 3 xx0103

AI 4 xx0104

AI 5 xx0105

AI 6 xx0106

AI 7 xx0107

AI 8 xx0108

AI 9 xx0201

AI 10 xx0202

AI 11 xx0203

AI 12 xx0204

DI 1 xx0301

DI 2 xx0302

DI 3 xx0303

DI 4 xx0304

DI 5 xx0305

DI 5 xx0305

shield

T x D
R x D
+5 V (Xi582), RTS (modem)

CTS
not used
GND
DTR
DCD
not used

Output voltage 24 V / 300 mA is
protected against short-circuiting.
After short-circuiting, it takes time
(approx. 60 sec.) for voltage to
recover.

24V relay module

(MCD3/MCE3, only!)

reserved

C+

system bus

C-

IMPORTANT

Do not connect system bus shield to earth. Use terminals 33 and 36.

NOTE: Use terminals 65 and 66 for relay modules MCD 3 or MCE 3 only.

Terminals 65 and 66 provide a pulsed 24 Vdc output which is not suitable
to connect direct relays.
Do not use reference voltage 10 V (terminal 67, 68) to supply other
devices.

AO 1 xx0401

AO 2 xx0402

AO 3 xx0403

AO 4 xx0404

AO 5 xx0405

AO 6 xx0406

AO 7 xx0407

AO 8 xx0408

AO 9 xx0501

AO 10 xx0502

AO 11 xx0503

AO 12 xx0504

DI 7 xx0307

DI 8 xx0308

DI 9 xx0309

DI 10 xx0310

DI 11 xx0311

DI 12 xx0312

alarm

(not used)

transformer

REF.

common

37
38
39
40

41

42

OUTPUTS

43
44
45
46
47
48
49
50

51
52
53
54
55
56
57
58
59
60

61
62
63
64

-

65

+

66

+

67

+

68
69
70

71
72

21-28 Vdc

ANALOG

DIGITAL

INPUTS

24 V_

300 mA

10 V

10 mA

24 Vac
+/-20%

or

EN1R-0144GE51 R1109 10

General Remarks about Electrical Connections

Observe all general VDE, NEC and local wiring regulations when making electrical
connections.

CAUTION

Electrical connection work is to be carried out by a qualified technician.

CAUTION

Using free terminals as support terminals can cause system damage.

Free terminals in the base plate must not be used as wiring support points under
any circumstances (danger of damage)! The electrical connection is to be made at
the base plate. The appropriate connection diagrams are on pages 10 and 11.
Further wiring diagrams are contained in the circuit diagrams.

IMPORTANT

Do not disconnect the Excel 100C controller from power supply for more
than 72 hours.

The Excel 100C is equipped with a gold capacitor buffer that holds the
RAM data and supplies the real-time clock for 72 hours in case of a power
outage. Beyond this period of time, all RAM data and time information are
lost.

EXCEL 100C INSTALLATION INSTRUCTIONS

Cable Routing

Minimum distance to mains cables:

10 mm (0.4 in.) All signal and output cables (low voltage) should be regarded as communication

circuits in accordance with VDE 0100, VDE 0800 and NEC, it should therefore be
routed separately from line voltage. Minimum distance 10 cm (4 in.) for unshielded
cable. Minimum distance 10 mm (0.4 in.) for shielded cable. Joining sensor cables
should be avoided.

Shielding of Sensor and Actuator Cables

Shielding of sensor and actuator cables with low protective voltages is not
necessary if the general guidelines on cable routing are observed (see "Cable
Routing" on page 11). If, under certain circumstances, the routing guidelines cannot
be observed, shielded cable must always be used.

IMPORTANT

Shielded cables must be grounded on one side only.

The grounding of the shielded cable must be as shown in the diagram.

Shielding on one sideat the control cabinet ground: Shielding of I/O cables

connected to peripherals such as
sensors and actuators must be
grounded at the control cabinet side,
only; this to avoid ground loops.

11 EN1R-0144GE51 R1109

EXCEL 100C INSTALLATION INSTRUCTIONS

Shielding of Data Transmitting Cables (System Bus and Operator Interface)

IMPORTANT

Data transmitting cables must always be shielded to prevent radio
interference.

1. System Bus Cables

Connect shield of system bus cable
on both sides System bus cables must be shielded on both sides at the base plate terminal 33

and 36 of the controller device. Connection to the control cabinet ground or other
ground points is not permitted (see WARNING below)!

2. Operator Interface (for external operating devices, only)

To connect remote operators units, ready-made cables are available (XW582,
XW584, XW585) with the shield already connected to the computer module plug
end.

For detailed information on cable types to be used in accordance with regional
requirements, please refer to the U.S. and European Specifications chapters.

System Ground

Primary: Secondary:

RFI Suppression

CB-0236b

WARNING

High voltage

Risk of electrical shock or equipment damage

The controller's system ground must have no connection with the control cabinet
ground!

NOTE: A document providing additional information on system grounding (if

Honeywell actuators are RFI-suppressed as a standard in accordance with
EN 50 081-1/EN 55 022.

demanded) is available via the Honeywell Technical Assistance Center
(TAC) or, for Honeywell employees, on the Docu Server under:
http://web.ge51.honeywell.de/dep/mc/TAC_Tips.

EN1R-0144GE51 R1109 12

Cable Lengths and Cross Sectional Areas

SFO

Cross sectional areas related to cable length

Table 2. Signal types and cross-sectional areas

EXCEL 100C INSTALLATION INSTRUCTIONS

Cabling of Actuator with 24 Vac

Supply and max. 550 ft (170 m)

IMPORTANT

For detailed information on cable types to be used in accordance to regional
requirements, please refer to the U.S. and European Specifications chapters.

PRIMARY
VOLTAGE

TRANSFORMER

type of signal

cross sectional area

 300 ft (100 m)  550 ft (170 m)  1300 ft (400 m)

power supply
(24 Vac)

low-current

 16 AWG

( 1.5 mm

2

)

 14 AWG

( 2.5 mm2)

 20 AWG ( 0.5 mm2)

-

signals*

*E.g. for 0-10 V sensors, totalizers, digital inputs, 0…10 V signals for actuators.

The max. length of a signal cable with 24 Vac supply is 550 ft (170 m).

The max. length of a two-wire, 0 to 10 Vdc signal cable is 1,300 ft (400 m).

The secondary side of the transformer must not be connected to earth
ground.

0000056c

24 Vac

24 V

Y

GND

MAX. 550 ft (170 m)

MIN. 14 AWG (2.5 mm )

2

Cabling of Actuator with 24 Vac Supply

from External Transformer and

max. 1,300 ft (400 m) If the distance between the controller and actuator or sensor with 24 Vac supply is

greater than 550 ft (170 m), a separate external transformer for the actuator or
sensor is necessary.

PRIMARY
VOLTAGE

230 Vac
120 Vac

TRANSFORMER

24 Vac

MAX. 1300 ft (400 m)

MIN.20 AWG (0.5 mm )

0 TO 10 Vdc

GND

24 Vac

2

EXTERNAL
TRAN

230 Vac
120 Vac

PRIMARY
VOLTAGE

RMER

00000057c

NOTE: The transformer must be chosen in accordance with specifications listed in

the U.S. and European Specifications chapters.

13 EN1R-0144GE51 R1109

EXCEL 100C INSTALLATION INSTRUCTIONS

a

IMPORTANT

Line Power Supply

The Excel 100C Controller is powered by an external transformer.

PRIMARY: SECONDARY:

230 Vac
120 Vac

24 Vac

+ 2 0 %

- 20 %

9
6
0
0
0
0
0

Transformer requirements for one Excel 100C Controller:

Secondary
Voltage 24 Vac 20% or 21-28 Vdc

Current 1.1 A

Power 15 VA (Excel 100C, only; no MCE/MCD)

25 VA (if fully equipped with MCE/MCD)

The transformer, already installed in the cabinet, can be used to supply several con­trollers, communication devices, or peripherals (e.g. actuators, etc.) – provided it
delivers sufficient power.

RIN-APU24 is supported.

For detailed information on transformers to be used in accordance to regional
requirements, please refer to the U.S. and European Specifications chapters.

We recommend installing a fuse on the secondary side of the transformer
in order to protect the devices against miswiring.

Standard Transformers

Requirements for standard transformers

Communication

EBI/SymmetrE

XL-ONLINE

C-BUS

Table 3. Requirements for standard transformers

output voltage impedance AC current

24.5 Vac to 25.5 Vac  1.15 Ω max. 2 A

24.5 Vac to 25.5 Vac  0.40 Ω max. 6 A

24.5 Vac to 25.5 Vac  0.17 Ω max. 12 A

Excel devices may communicate in different modes and lines. The principal
communication scheme is shown in the accompanying figure.

EBI/SymmetrE

Excel 100C

OTHER

CONTROLLERS

Modem/ISDN

COMMUNICATION

Modem/ISDN

Excel 500 Excel 600

Modem

XI581/582

(providing bus-wide
access to all devices
connected to C-Bus)

EN1R-0144GE51 R1109 14

Excel 100C Excel 100C